Muscle or joint support article

ABSTRACT

The present application generally relates to support articles and methods of making and using them. Some embodiments of the support articles of the present disclosure provide compression and/or stabilization to sore joints, tendons, or muscles. In some embodiments, the compression and/or enhanced stabilization is provided, at least in part, by one or more reinforcing portions. In some embodiments, the support articles can easily be applied by a non-trained user and can be worn in many conditions (including, for example, in the shower or during exercise) for up to three days. In some embodiments, the support articles or support articles also have a relatively slim profile and are thus discreet such that they can be worn under clothing without being noticeable. In some embodiments, the support articles eliminate or reduce joint or muscle pain or soreness.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a national stage filing under 35 U.S.C. 371 ofPCT/US2017/063358, filed Nov. 28, 2017, which claims the benefit ofprovisional Application No. 62/579,268, filed Oct. 31, 2017, and alsoclaims the benefit of provisional Application No. 62/429,355, filed Dec.2, 2016, the disclosure of which is incorporated by reference inits/their entirety herein.

TECHNICAL FIELD

The present application generally relates to support articles andmethods of making and using them.

BACKGROUND

A strained or injured muscle or joint not only causes pain anddiscomfort, but can make someone feel slower or weaker than normal, allof which can interfere with daily living activities. As such,maintaining healthy skeletal muscles is essential to keeping peoplemoving at their best. Historically, those with injuries or discomfortwere instructed to limit or eliminate movement of the injured muscle,tendon, or joint. Today we know that, generally, keeping muscles movingimproves circulation, can reduce pain, and/or speeds healing. Over thepast twenty years, many innovative devices and techniques have come outof kinesiology science (the science behind muscular and skeletalmovement) to help protect and treat injured or sore muscles, tendons,and joints.

Compression wraps, sleeves, and braces offer stabilization of themuscles and joints covered by the wraps, sleeves, and braces.Additionally or alternatively, compression wraps, sleeves, and braceshelp to reduce pain, swelling, and cramping by increasing circulationand/or reducing fatigue. More specifically, an injured muscle oftenswells as a result of a build-up of fluid. The fluid build-up canprevent blood from circulating to the injured area, which results inslowing the healing process. Compression therapy generally uses asnug-fitting device to put pressure on the impacted area. The pressurereduces swelling and/or increases circulation by forcing fluid in theimpacted area to move back into the blood vessels. As a result, theswelling decreases. Once the swelling has decreased, blood flow mayreturn to the area and promote healing.

Kinesiology tapes (KT tapes) gently lift the skin and tissue attached toan injured muscle so that blood and other body fluids can move morefreely in and around that muscle. Additionally, KT tapes can createneuromuscular feedback (called proprioception) that inhibits (relaxes)or facilitates stronger firing of muscles and tendons. This feedbackcreates support elements without the bulk and restriction commonlyassociated with wraps and heavy bracing.

SUMMARY

The inventors of the present disclosure recognized that existingcommercial compression and kinesiology tape offerings have somedisadvantages. For example, braces and compression sleeves, while highlyeffective, are bulky and can be challenging to wear discreetly underclothing. Further, braces and compression sleeves can be a significantmonetary investment, and/or can get dirty and sweaty during prolongeduse. Compression tapes and/or wraps can be challenging fornon-professionally trained users to correctly apply at the correcttightness, potentially limiting their effectiveness and/or causing painor harm. Kinesiology tapes provide good neuromuscular feedback but donot provide significant compression. Further, their ability to providestabilization is somewhat limited.

The inventors of the present disclosure sought to create disposable andrelatively inexpensive support articles that offer the best features ofbraces, compression sleeves, compression wraps, and kinesiology tapeswhile eliminating or minimizing their drawbacks. The inventors of thepresent disclosure sought to create support articles that offer muscleor joint stabilization similar to a brace, muscle or joint compressionsimilar to a compression wrap, and/or the slim, discreet profile andneuromuscular feedback of kinesiology tapes.

In some embodiments, the support articles of the present disclosureprovide compression and/or stabilization of sore joints or muscles. Insome embodiments, the compression and/or enhanced stabilization isprovided, at least in part, by one or more reinforcing portions on thesupport article. In some embodiments, the support article is a patch,cover, sheet, or strip. In some embodiments, the support article isnoncircumferential (in other words, it does not extend around thecircumference of a body part such as, for example, an ankle, leg, arm,etc. in the way that an elastic bandage (e.g. . . . Ace™ bandage),elastic wrap, or compression roll would extend around the circumferenceof the body part). In some embodiments, the support articles can easilybe applied by a non-trained user and/or can be worn in many conditions(including, for example, in the shower or during exercise) for up tothree days. The support articles also have a relatively slim profile andare thus discreet such that they can be worn under clothing withoutbeing noticeable. Some support articles of the present disclosure aredisposable after use. Further, some disposable support articles costsignificantly less than a brace or compression sleeve. In someembodiments, the support articles eliminate or reduce joint or musclepain or soreness. In some embodiments, the support articles eliminate orreduce joint or muscle swelling. In some embodiments, the supportarticles have a shape and size tailored for a specific body area. Insome embodiments, the support articles are easy to apply and removeeasily and/or without pain.

Some embodiments relate to a support article, comprising a backinghaving a front major surface and a rear major surface; an adhesiveadjacent to least a portion of the rear major surface of the backing,the adhesive capable of adhering the support article to the user, andone or more reinforcing portions adjacent to at least a portion of therear major surface of the backing or the front major surface of thebacking.

Some embodiments relate to a method of applying a support article,comprising: removing a liner from a rear major surface of the supportarticle to expose an adhesive, positioning the support article adjacentto a user's body in a desired location; applying the support article tothe user such that the adhesive contacts the user's skin, and puttingpressure on the support article to cause the adhesive to adhere to theuser's skin.

Any of the embodiments described herein can include a release lineradjacent to at least a portion of the adhesive. Any of the embodimentsdescribed herein can include a backing including at least one of apolyurethane film, a polyethylene film, a polypropylene film, a PVCfilm, a nonwoven material, and/or a woven material. Any of theembodiments described herein can include a backing including at leastone of a polyolefin, polyester, polyalkylene, polyamide, polystyrene,polyarylsulfone, polydiene, and/or polyurethane. Any of the embodimentsdescribed herein can include a backing including conjugatemulticomponent melt spun fibers. Any of the embodiments described hereincan include a backing having a weight of between about 25 gsm to about300 gsm. Any of the embodiments described herein can include the backinghaving a thickness of about 0.01 cm to about 1 cm.

Any of the embodiments described herein can include at least one of thebacking or the backing and adhesive combination having a breathabilityand/porosity of between about 3 and about 12 mm H₂O measured using thepressure drop test. Any of the embodiments described herein can includeat least one of the backing or the backing and adhesive combinationhaving a cross-directional tensile strength of between about 4 lbf (17.8N) and about 9 lbf (40.0 N) and/or a machine-directional tensilestrength of between about 5 lbf (22.2 N) and about 10 lbf (44.5 N). Anyof the embodiments described herein can include at least one of thebacking or the backing and adhesive combination having across-directional elongation at break of between about 600% and about900% and/or a machine-directional elongation at break of between about350% and about 1000%. Any of the embodiments described herein caninclude the backing and adhesive forming a conjugate multicomponentsystem. Any of the embodiments described herein can include thereinforcing portion(s) covering between about 10% and about 75% of thetotal surface area of the backing.

Any of the embodiments described herein can include the adhesiveadhering the one or more reinforcing portions to the front or rear majorsurface of the backing. Any of the embodiments described herein caninclude the adhesive being a pressure sensitive adhesive and beingselected from at least one of the following adhesive classes:polyacrylate adhesives, polyalphaolefin adhesives, polyvinyl acrylates,rubber resin adhesives, silicone adhesives, polydiorganosiloxanepolyurea compolymers, and mixtures thereof.

Any of the embodiments described herein can include the one or morereinforcing portions including at least one of foam or a shaped memorymaterial. Any of the embodiments described herein can include the one ormore reinforcing portions comprising: an adhesive layer having first andsecond major surfaces; a first foam layer adjacent to first majorsurface of the adhesive layer; a second foam layer adjacent to secondmajor surface of the adhesive layer; a first skin layer adjacent tofirst foam layer; and a second skin layer adjacent to second foam layer.Any of the embodiments described herein can include microspheres in atleast one of the first or second foam layers. Any of the embodimentsdescribed herein can include the one or more reinforcing portions havinga Shore A hardness is between about 10 and about 100 when measuredaccording to ASTM D2240 and/or a Shore D hardness of between about 10and about 60 when measured according to ASTM D2240. Any of theembodiments described herein can include the one or more reinforcingportions having a cross-directional tensile strength of between about 13lbf (57.8 N) and about 28 lbf (129.0 N) and/or a machine-directionaltensile strength of between about 16 lbf (71.2 N) and about 31 lbf(137.9 N). Any of the embodiments described herein can include the oneor more reinforcing portions having a thickness of between about 2 cm(787 mil) and about 0.051 cm (20 mil). Any of the embodiments describedherein can include the one or more reinforcing portions having anelongation at break of between about 10% and about 50%. Any of theembodiments described herein can include at least two reinforcingportions that are on layered on one another. Any of the embodimentsdescribed herein can include at least one of the reinforcing portionsbeing separate from the support article and being independently appliedby the user before the full support article is applied. article andbeing independently applied by the user before the full support articleis applied.

Any of the embodiments described herein can include the support articlehaving a weight of between about 20 gsm and about 500 gsm. Any of theembodiments described herein can include a support article applied to orsized for application to at least one of the IT band, hip, calf, shin,quads, hamstrings, groin, hip flexor, gluteus, outer knee, inner knee,Osgood shlatter, back of knee, front of knee, Achilles tendon, ankle,ball of foot, top of foot, heel, toe, finger, SI joint, low back, middleback, ribs, spine, abdominal, neck, shoulder, rotator cuff, AC joint,wrist, elbow, thumb, bicep, and/or tricep.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a top view of one exemplary embodiment of a support article inaccordance with the teachings of the present disclosure.

FIG. 2A is rear view of the support article shown in FIG. 1; FIG. 2B isa cross-sectional side view of the support article of FIG. 2A.

FIG. 3 is a front view of another exemplary embodiment of a supportarticle in accordance with the teachings of the present disclosure.

FIG. 4 is a rear view of the support article of FIG. 3.

FIG. 5 is a rear view of another exemplary embodiment of a supportarticle in accordance with the teachings of the present disclosure.

FIG. 6 is a rear view of another exemplary embodiment of a supportarticle in accordance with the teachings of the present disclosure.

FIG. 7 is a schematic drawing of the support article of the typegenerally shown in FIGS. 1-6 in use.

FIGS. 8A and 8B are respective front and rear views of another exemplaryembodiment of a support article in accordance with the teachings of thepresent disclosure.

FIG. 9 is a schematic drawing of the support article of FIGS. 8A and 8Bin use and/or during application.

FIG. 10 is a front view of another exemplary embodiment of a supportarticle in accordance with the teachings of the present disclosure.

FIGS. 11A, 11B, and 11C are rear views of three additional exemplaryembodiments of support articles in accordance with the teachings of thepresent disclosure.

FIG. 12 is a schematic drawing of a support article as generally shownin any of FIGS. 10-11C in use.

FIGS. 13A and 13B are respective front and rear views of anotherexemplary embodiment of a support article in accordance with theteachings of the present disclosure.

FIGS. 14A-14E are schematic drawings showing how to apply the supportarticle of any of FIGS. 13A through 13B.

FIGS. 15A and 15B are respective front and rear views of anotherexemplary embodiment of a support article in accordance with theteachings of the present disclosure.

FIGS. 16A-16D are schematic drawings showing how to apply the supportarticle of any of FIGS. 15A through 15B.

FIGS. 17A and 17B are respective front and rear views of anotherexemplary embodiment of a support article in accordance with theteachings of the present disclosure.

FIG. 18 is a schematic drawing of the support article of FIGS. 17A and17B in use.

FIGS. 19A and 19B are respective front (top) and rear (bottom) views ofanother exemplary embodiment of a support article in accordance with theteachings of the present disclosure.

FIGS. 20A and 20B are respective front (top) and rear (bottom) views ofanother exemplary embodiment of a support article in accordance with theteachings of the present disclosure.

FIGS. 21A and 21B are respective front (top) and rear (bottom) views ofanother exemplary embodiment of a support article in accordance with theteachings of the present disclosure.

FIGS. 22A and 22B are respective front (top) and rear (bottom) views ofanother exemplary embodiment of a support article in accordance with theteachings of the present disclosure.

FIGS. 23A and 23B are respective front (top) and rear (bottom) views ofanother exemplary embodiment of a support article in accordance with theteachings of the present disclosure.

FIGS. 24A and 24B are respective front (top) and rear (bottom) views ofanother exemplary embodiment of a support article in accordance with theteachings of the present disclosure.

FIG. 25 is a cross-sectional schematic drawing of an exemplaryreinforcing portion that can be used in the support articles of thepresent disclosure.

In the following detailed description, reference may be made to theabove-described set of drawings in which are shown by way ofillustration several exemplary embodiments. It is to be understood thatother embodiments are contemplated and may be made without departingfrom the scope or spirit of the present disclosure.

DETAILED DESCRIPTION

Various embodiments and implementations will be described in detail.These embodiments should not be construed as limiting the scope of thepresent application in any manner, and changes and modifications may bemade without departing from the spirit and scope of the inventionsdescribed herein. Further, only some end uses have been discussedherein, but end uses not specifically described herein are includedwithin the scope of the present application. For example, the supportarticle is often referred to herein as a patch. A patch is merely oneexemplary embodiment. As used herein, the term “patch” refers to a pieceof material used to cover an injured or sensitive area of the body. Thepatch preferably has adherent properties such that it can adhere to theinjured or sensitive area of the body. The term patch does not requirethe presence of a medicament, although, as is described in more detailherein, the embodiments described herein could include a medicament. Assuch the scope of the present application should be determined by theclaims.

The present disclosure generally relates to support articles. In someembodiments, the support article is a patch that, when applied,eliminates or reduces joint or muscle pain, soreness, and/or swellingand/or increases mobility and/or stability.

In some embodiments, the support article has a shape and size tailoredfor a specific body area. In some embodiments, the support article canbe used in any of the following exemplary body areas: IT band, hip,calf, shin, quads, hamstrings, groin, hip flexor, gluteus, outer knee,inner knee, Osgood shlatter, back of knee, front of knee, Achillestendon, ankle, ball of foot, top of foot, arch, foot heel, toe, finger,SI joint, low back, middle back, ribs, spine, abdominal, neck, shoulder,rotator cuff. AC joint, wrist, elbow, thumb, trapezius, bicep, and/ortricep. In some embodiments, the support article has a more general useand a single shape or design can be used in a number of different bodyareas.

FIGS. 1-7 show various support article embodiments that can be used, forexample, as shoulder support articles (as shown more specifically inFIG. 7). FIGS. 1 and 2A are respective front and rear views of oneexemplary embodiment of a support article in accordance with theteachings of the present disclosure. FIG. 2B is a cross-sectional sideview of the support article shown in FIGS. 1 and 2A. Support article 100includes a backing 110 in the shape generally shown. The shape generallyincludes an elongate middle portion 180 that terminates in two wingportions, first and second wing portions 182, 184. The front (or top)major surface of backing 110 is shown in FIG. 1. As shown in FIG. 2B,the back (or rear or bottom) major surface of backing 110 is at leastpartially coated with or adjacent to an adhesive 230 and to at least onereinforcing portion 220. In the specific embodiment shown in FIGS. 2Aand 2B, there are two reinforcing portions 220. Any desired number,shape, size, or thickness reinforcing portion may be used.

FIGS. 3 and 4 are respective top (or front) and rear (or bottom or back)views of another exemplary embodiment of a shoulder support article inaccordance with the teachings of the present disclosure. Support article300 includes a backing 310 in the general shape shown. The shapegenerally includes an elongate middle portion 380 that terminates in twowing portions, first and second wing portions 382, 384. FIGS. 4, 5, and6 are rear (or back or bottom) views of three alternative exemplarembodiments of support article 300 of FIG. 3. FIGS. 4, 5, and 6 allinclude differently numbered and/or shaped reinforcing portions on therear (or back or bottom) surface of backing 310. The support article300A of FIG. 4 includes a single reinforcing portion 420. The supportarticle 300B of FIG. 5 includes four reinforcing portions 520, all ofwhich are differently shaped and sized from the others. Support article300C of FIG. 6 includes fourteen reinforcing portions 620 that are alldifferently shaped and sized from one another. The back (or rear orbottom) major surface of backing 310 is at least partially coated withor adjacent to an adhesive 330 that will adhere the support article tothe users skin and which, in some embodiments, may also adhere the oneor more reinforcing portions 320, 520, or 620 to backing 310.

FIG. 7 is a schematic drawing of the support article of the typegenerally shown in FIGS. 3 and 5 in use on a human's shoulder. In thisembodiment, elongate body portion 380 is applied on the user's upper armsuch that the area where elongate body portion 380 contacts first andsecond wing portions 382, 384 is generally over or adjacent to theshoulder joint area. Each of first and second wings 382, 384 extendanteriorly and posteriorly (or toward the user's front and toward theuser's back, respectively) from the user's shoulder region. Wings 382,384 help to anchor the support article over the shoulder area.

The shoulder support embodiments shown in FIGS. 1-7 are merely exemplaryand may be modified in any way described herein and/or obvious to thoseof skill in the art. For example, any desired number, shape, size, orthickness reinforcing portion may be used. Any desired shape, size, orthickness backing may be used. Any of the backings, adhesives, and/orreinforcing portions described herein can be used. Any adhesive capableof use on skin can be used, as is discussed in greater detail herein.The reinforcing portions can be adhesively attached or adhered to thebacking or can be mechanically attached or adhered to the backing, as isdescribed in greater detail herein. An optional release liner (notshown) may be positioned adjacent to at least a portion of the adhesiveand/or backing. The release liner may extend over the reinforcingportions or may have a cut out around reinforcing portions. The supportarticle positioning on the body may differ.

FIGS. 8-9 show an exemplary support article embodiment that can be used,for example, as a knee support article (as shown more specifically inFIG. 9). FIGS. 8A and 8B are respective front (or top) and rear (or backor bottom) views of an exemplary embodiment of a support article inaccordance with the teachings of the present disclosure. Support article800 includes a backing 810 in the shape shown, which can be generallydescribed as an elongated u-shape. One or more reinforcing portions 820are adhered or attached to at least a portion of the rear (or back orbottom) major surface of backing 810. The specific exemplary embodimentof FIG. 8B includes two reinforcing portions 820. Also, the back (orrear or bottom) major surface of backing 810 is at least partiallycoated with or adjacent to an adhesive 830 that will adhere the supportarticle to the users skin and which, in some embodiments, may alsoadhere the one or more reinforcing portions 820 to backing 810.

FIG. 9 is a schematic drawing of support article 800 in use on a human'sknee. In this specific embodiment, the concavity of the u-shaped supportarticle is positioned generally underneath the user's kneecap. Thispositioning provides support to the user's knee during movement and/orcompression and pressure to reduce swelling, etc. To apply the supportarticle, the liner (where present) is removed and the support article ispositioned below the kneecap. The support article is then positioneddirectly adjacent to the skin such that it adheres to the skin, belowthe knee. This can most easily be done by the user grasping the twoopposing major ends of the support article while directing the supportarticle to the desired position below the kneecap.

By grasping the two ends of the support article as shown in FIG. 9, theuser can create a desired amount of compression and pressure on theaffected area by tailoring the placement of the support article to theimpacted area. For example, by pulling the opposing long ends of thesupport article to their maximum width and then applying the supportarticle, additional or maximum compression and/or pressure on theimpacted area can be obtained. This is because the support article willspring back or contract slightly once applied, thereby creatingadditional or maximum pressure or compression on the impacted area. Bycontrast, the user can hold the two opposing ends in their naturalposition and apply the support article, which will provide compressionand/or pressure, but less compression and/or pressure than applied byextending the opposing ends to their maximum width during application.In at least this way, the support article can be tailored to applydifferential compression, support, or pressure as dictated by the user'sdesires, the specific injury or affected area needs, and the user'sapplication techniques. The ability for the support articles to providedifferential or tailored pressure, compression, and/or support is trueof all embodiments described herein; not just this specific embodiment.

The knee support embodiments shown in FIGS. 8-9 are merely exemplary andmay be modified in any way described herein and/or obvious to those ofskill in the art. For example, any desired number, shape, size, orthickness reinforcing portion may be used. Any desired shape, size, orthickness backing may be used. Any of the backings, adhesives, and/orreinforcing portions described herein can be used. Any adhesive capableof use on skin can be used, as is discussed in greater detail herein.The reinforcing portions can be adhesively attached or adhered to thebacking or can be mechanically attached or adhered to the backing, as isdescribed in greater detail herein. An optional release liner (notshown) may be positioned adjacent to at least a portion of the adhesiveand/or backing. The release liner may extend over the reinforcingportions or may have a cut out around reinforcing portions. The supportarticle positioning on the body may differ.

FIGS. 10-12 show various exemplary support article embodiments that canbe used, for example, as elbow support articles (as shown morespecifically in FIG. 12). FIG. 10 is a front (or top) view of anexemplary embodiment of a support article in accordance with theteachings of the present disclosure. Support article 1000 includesbacking 1010 in the shape shown. The exemplary shape shown is generallytriangular with an apex portion 1060 and two side (or wing) portions1070, 1075 (also referred to as first and second side or wing portions,respectively).

FIGS. 11A, 11B, and 11C are rear (or back or bottom) views of threealternative exemplary embodiments of support article 1000 of FIG. 10.FIGS. 11A, 11B, and 11C all include differently numbered and/or shapedreinforcing portions on the rear (or back or bottom) surface of backing1010. The one or more reinforcing portions are adhered or attached to atleast a portion of the rear (or back or bottom) major surface of backing1010. Also, the back (or rear or bottom) major surface of backing 1010is at least partially coated with or adjacent to an adhesive 1130 thatwill adhere the support article to the users skin and which, in someembodiments, may also adhere the one or more reinforcing portions tobacking 1010. The support article 1000A of FIG. 11A includes a singlereinforcing portion 1120A. The support article 1000B of FIG. 11Bincludes three reinforcing portions 1120B, two of which are similarlyshaped and sized and one of which is differently shaped and sized fromthe other two. Support article 1000C of FIG. 11C includes threereinforcing portions 1120C that are all similar or the same shape, size,and spacing from one another.

FIG. 12 is a schematic drawing of the elbow support article of the typegenerally shown in any of FIGS. 10-11C in use on a human's arm/elbow. Inthis specific embodiment, apex portion 1060 is positioned toward theuser's upper arm and first and second side portions 1070, 1075 extendaround opposing sides of the upper portion of the user's forearm (orlower arm). Notably, this is merely on exemplary positioning of thesupport article and others may be used.

The elbow support embodiments shown in FIGS. 10-12 are merely exemplaryand may be modified in any way described herein and/or obvious to thoseof skill in the art. For example, any desired number, shape, size, orthickness reinforcing portion may be used. Any desired shape, size, orthickness backing may be used. Any of the backings, adhesives, and/orreinforcing portions described herein can be used. Any adhesive capableof use on skin can be used, as is discussed in greater detail herein.The reinforcing portions can be adhesively attached or adhered to thebacking or can be mechanically attached or adhered to the backing, as isdescribed in greater detail herein. An optional release liner (notshown) may be positioned adjacent to at least a portion of the adhesiveand/or backing. The release liner may extend over the reinforcingportions or may have a cut out around reinforcing portions. The supportarticle positioning on the body may differ.

FIGS. 13A-13B show an exemplary support article embodiment that can beused, for example, as a wrist support article. Use and application ofthe wrist support article are shown in FIGS. 14A-14E. FIGS. 13A and 13Bare respective front (or top) and rear (or bottom or back) views of anexemplary embodiment of a support article in accordance with theteachings of the present disclosure. Support article 1300 includesbacking 1310 in the shape shown. This specific shape has a top portion1360 opposite a bottom portion 1365 and two opposing side (or wing)portions 1370 and 1375 (which can be called first and second side orwing portions) extending from the middle or center portion 1380 ofsupport article 1300 between top portion 1360 and bottom portion 1365.

FIG. 13B shows the rear surface of support article 1300 and includesreinforcing portion 1320 and adhesive 1330. Reinforcing portion 1320 isadhered or attached to at least a portion of the rear (or back orbottom) major surface of backing 1310. The specific exemplary embodimentof FIG. 13B includes a single reinforcing portion. Also, the back (orrear or bottom) major surface of backing 1310 is at least partiallycoated with or adjacent to an adhesive 1330 that will adhere the supportarticle to the users skin and which, in some embodiments, may alsoadhere the one or more reinforcing portions 1320 to backing 1310.

FIGS. 14A-14E schematically show support article 1300 of FIGS. 13A and13B during application and in use on a human's wrist. FIG. 14A showsremoval of at least some of the release liner (where present). In thisexemplary embodiment, the support article includes multiple, separatelycut release liners. The use of separately cut release liners facilitateseasy application of the support article. In the specific embodimentshown in FIG. 14A, a portion of the release liner that corresponds totop portion 1360 of support article 1300 is removed. FIG. 14B showsplacement of top portion 1360 (and optionally some of middle portion1380) of support article 1300, whose release liner was removed, adjacentto the hand/upper wrist area of the user. After placement, the user maypress the applied portion of the support article onto the skin to ensurea good fit and/or adherence. In some embodiments, the support article ispreferably positioned such that the reinforcing portion 1320 ispositioned adjacent to a sore, injured, or affected area. This placementensures that the maximal pressure or compression provided by supportarticle 1300 is applied to the sore, injured, or affected area tomaximize reduction in pain, increased blood flow, decreased swelling,etc. in that area. Next, but not shown, the user removes another portionof the release liner from support article 1300. In this specificexemplary embodiment, a portion of the release liner that corresponds tobottom portion 1365 of support article 1300 is removed. FIG. 14C showsplacement of bottom portion 1365 (and optionally some of middle portion1380) of support article 1300, whose release liner was removed, adjacentto the forearm/lower wrist area of the user. The user is shown pressingthe applied portion of the support article onto the skin to ensure agood fit and/or adherence. Next, but not shown, the user removes one orboth of the two side (or wing) portions of the release liner fromsupport article 1300. The user than wraps the side (or wing) portion(s)around the forearm and presses on them to ensure a good fit/adherence ofthe support article to the affected area. FIG. 14E shows support article1300 in place once all application steps are complete. Those of skill inthe art will appreciate that this is merely one exemplary applicationprocess and other processes or methods may be used without departingfrom the scope of the present disclosure.

The wrist support embodiments shown in FIGS. 13-14 are merely exemplaryand may be modified in any way described herein and/or obvious to thoseof skill in the art. For example, any desired number, shape, size, orthickness reinforcing portion may be used. Any desired shape, size, orthickness backing may be used. Any of the backings, adhesives, and/orreinforcing portions described herein can be used. Any adhesive capableof use on skin can be used, as is discussed in greater detail herein.The reinforcing portions can be adhesively attached or adhered to thebacking or can be mechanically attached or adhered to the backing, as isdescribed in greater detail herein. The release liner can be in anyshape or size, including in a single or multiple pieces. The releaseliner may extend over the reinforcing portions or may have a cut outaround reinforcing portions. The method of application may differ. Thesupport article positioning on the body may differ.

FIGS. 15-16 show an exemplary support article embodiment that can beused, for example, as a trapezius support article (as shown morespecifically in FIGS. 16A-16D). FIGS. 15A and 15B are respective front(or top) and rear (or bottom or back) views of an exemplary embodimentof a support article in accordance with the teachings of the presentdisclosure. Support article 1500 includes backing 1510 in the shapeshown. This specific shape has a top portion 1560 opposite from andslightly wider than a bottom portion 1565.

FIG. 15B shows the rear surface of support article 1500 and includesreinforcing portion 1520 and adhesive 1530. Reinforcing portion 1520 isadhered or attached to at least a portion of the rear (or back orbottom) major surface of backing 1510. The specific exemplary embodimentof FIG. 15B includes a single reinforcing portion. Back (or rear orbottom) major surface of backing 1510 is at least partially coated withor adjacent to an adhesive 1530 that will adhere the support article tothe users skin and which, in some embodiments, may also adhere the oneor more reinforcing portions 1520 to backing 1510.

FIGS. 16A-16D schematically show the support article of FIGS. 15A and15B during application and in use on a human's trapezius. FIG. 16A showsremoval of at least some of the release liner (where present). In thisexemplary embodiment, the support article includes multiple, separatelycut release liners. The use of separately cut release liners facilitateseasy application of the support article. In the specific embodimentshown in FIG. 16A, a portion of the release liner that corresponds totop portion 1560 of support article 1500 is removed. FIG. 16B showsplacement of top portion 1560 of support article 1500, whose releaseliner was removed, adjacent to the trapezius area of the user. In someembodiments, the support article is preferably positioned such that thereinforcing portion 1520 is positioned adjacent to a sore, injured, oraffected area. This placement ensures that the maximal pressure orcompression provided by support article 1500 is applied to the sore,injured, or affected area to maximize reduction in pain, increased bloodflow, decreased swelling, etc. in that area. After placement, the usermay press the applied portion of the support article onto the skin toensure a good fit and/or adherence. Next, but not shown, the userremoves another portion of the release liner from support article 1500.In this specific exemplary embodiment, a portion of the release linerthat corresponds to bottom portion 1565 of support article 1500 isremoved. FIG. 16C shows placement of bottom portion 1565 of supportarticle 1500, whose release liner was removed, adjacent to the anteriorarea of the upper trapezius toward the clavicle of the user. In FIG.16D, the user is shown pressing the applied portion of the supportarticle onto the skin to ensure a good fit and/or adherence.

The trapezius support embodiments shown in FIGS. 15-16 are merelyexemplary and may be modified in any way described herein and/or obviousto those of skill in the art. For example, any desired number, shape,size, or thickness reinforcing portion may be used. Any desired shape,size, or thickness backing may be used. Any of the backings, adhesives,and/or reinforcing portions described herein can be used. Any adhesivecapable of use on skin can be used, as is discussed in greater detailherein. The reinforcing portions can be adhesively attached or adheredto the backing or can be mechanically attached or adhered to thebacking, as is described in greater detail herein. The release liner canbe in any shape or size, including in a single or multiple pieces. Therelease liner may extend over the reinforcing portions or may have a cutout around reinforcing portions. The method of application may differ.The support article positioning on the body may differ.

FIGS. 17A, 17B, and 18 show various exemplary support articleembodiments that can be used, for example, as thumb support articles (asshown more specifically in FIG. 18). FIG. 17A is a front (or top) viewof an exemplary embodiment of a support article in accordance with theteachings of the present disclosure. Support article 1700 includesbacking 1710 in the shape shown. The exemplary shape shown is generallytriangular with an apex portion 1760 and two side (or wing) portions1770, 1775 (also referred to as first and second side or wing portions,respectively).

FIG. 17B is a rear (or back or bottom) view of an exemplary embodimentof support article 1700 of FIG. 17A. A reinforcing portion 1720 is onthe rear (or back or bottom) surface of backing 1710. The reinforcingportion 1720 is adhered or attached to at least a portion of the rear(or back or bottom) major surface of backing 1710. Also, the back (orrear or bottom) major surface of backing 1710 is at least partiallycoated with or adjacent to an adhesive 1730 that will adhere the supportarticle to the users skin and which, in some embodiments, may alsoadhere the one or more reinforcing portions to backing 1710.

FIG. 18 is a schematic drawing of the thumb support article of the typegenerally shown in FIGS. 17A and 17B in use on a human's thumb. In thisspecific embodiment, apex portion 1760 is positioned toward the user'sthumb and first and second side (or wing) portions 1770, 1775 extendaround opposing sides of the user's palm/hand. Notably, this is merelyon exemplary positioning of the support article and others may be used.

The thumb support embodiment shown in FIGS. 17A, 17B, and 18 is merelyexemplary and may be modified in any way described herein and/or obviousto those of skill in the art. For example, any desired number, shape,size, or thickness reinforcing portion may be used. Any desired shape,size, or thickness backing may be used. Any of the backings, adhesives,and/or reinforcing portions described herein can be used. Any adhesivecapable of use on skin can be used, as is discussed in greater detailherein. The reinforcing portions can be adhesively attached or adheredto the backing or can be mechanically attached or adhered to thebacking, as is described in greater detail herein. An optional releaseliner (not shown) may be positioned adjacent to at least a portion ofthe adhesive and/or backing. The release liner may extend over thereinforcing portions or may have a cut out around reinforcing portions.The support article positioning on the body may differ.

FIGS. 19A and 19B show an exemplary support article embodiment that canbe used, for example, as waist/back support article. FIGS. 19A and 19Brespectively show the front (or top) and rear (or bottom or back) viewsof an exemplary embodiment of a support article in accordance with theteachings of the present disclosure. Support article 1900 includesbacking 1910 in the shape shown. The exemplary shape shown is generallya rounded rectangle or stadium shape.

The rear surface of support article 1900 also includes adhesive 1930.First reinforcing portion 1920 is adhered or attached to at least aportion of the rear (or back or bottom) major surface of backing 1910.Reinforcing portion 1922 is adhered or attached to at least a portion ofreinforcing portion 1920. In this exemplary embodiment, firstreinforcing portion 1920 is generally stadium (or rounded rectangle)shaped, and second reinforcing portion 1922 is generally circular inshape. Back (or rear or bottom) major surface of backing 1910 is atleast partially coated with or adjacent to an adhesive 1730 that willadhere the support article to the users skin and which, in someembodiments, may also adhere the one or more reinforcing portions 1920to backing 1910.

FIG. 19B shows the rear surface of support article 1900 and includes afirst reinforcing portion 1920 and a second reinforcing portion 1922 ontop of first reinforcing portion. One benefit or advantage of havinglayered or stacked reinforcing portions is that the points where thereinforcing portions are layered or stacked can provide increased and/ordifferential compression and/or pressure. This can also provide, forexample, one or more targeted point pressures, which can assist in painand/or swelling reduction.

In some embodiments, first and second reinforcing portions 1920, 1922are adhered or attached to the backing at the time the user purchasesthe support article and/or during manufacturing of the support article.In some alternative embodiments, second reinforcing portion 1922 is notattached or adhered to the support article but is instead provided orsold separately. In such embodiments, the second reinforcing portioncould comprise a backing (any backing described herein) attached oradhered to a reinforcing portion (any reinforcing portion describedherein attached or adhered using any method or attachment means ormechanism described herein) or merely a reinforcing portion. Theuppermost (or exposed) surface of the reinforcing portion (in eitherimplementation) could be coated (at least partially) with adhesivecapable of allowing the second reinforcing portion to adhere to theuser. The user could then adhere one or more second (or separate)reinforcing portions directly to the injured, swollen, impacted, oraffected area. After doing so, the user would then apply the supportarticle over and adjacent to the second (or separate) reinforcingportions.

These embodiments that include one or more second reinforcing portionsmay permit the application of maximum pressure to the injured, swollen,impacted, or affected area. These embodiments could also providetargeted, point pressure as needed and at the user's option. Theseembodiments could also provide differential pressure (greater pressurein the areas with the one or more second (or separate) reinforcingportions than the pressure under the support article) as needed and atthe user's option. These embodiments could also provide areas ortargeted compression where the second (or separate) reinforcing portionswere positioned and areas of tape-like lift in areas where the supportarticle was located. These embodiments could also provide ease inapplication in areas of the body where correct positioning can bechallenging to achieve.

FIG. 19A schematically shows support article 1900 in use on a human'swaist/back.

The waist/back support embodiment shown in FIGS. 19A and 19B is merelyexemplary and may be modified in any way described herein and/or obviousto those of skill in the art. For example, any desired number, shape,size, or thickness reinforcing portion(s) may be used. For example, thesupport article may additionally include one or more of third, fourth,firth, etc. reinforcing portions. It can include more than the singlesecond reinforcing portion shown. These can be part of the supportarticle at the time of manufacturing and/or purchase or can be separate.In instances where they are separate, they can be applied by the userseparate from the support article. In such instances, they may becomepart of the support article once the user applies them and they alladhere, attach, or are placed adjacent to one another. For purposes ofclarity, multiple reinforcing portions (spaced apart or layered on eachother) may be used in any of the embodiments or implementationsdescribed herein. Any desired shape, size, or thickness backing may beused. Any of the backings, adhesives, and/or reinforcing portionsdescribed herein can be used. Any adhesive capable of use on skin can beused, as is discussed in greater detail herein. The reinforcing portionscan be adhesively attached or adhered to the backing or can bemechanically attached or adhered to the backing, as is described ingreater detail herein. The release liner can be in any shape or size,including in a single or multiple pieces. The release liner may extendover the reinforcing portions or may have a cut out around reinforcingportions. The support article positioning on the body may differ.

FIGS. 20A and 20B show an exemplary support article embodiment that canbe used, for example, as a lower back support article. FIGS. 20A and 20Bare respective front (or top) and rear (or bottom or back) views of anexemplary embodiment of a support article in accordance with theteachings of the present disclosure. FIG. 20A schematically showssupport article 2000 in use on the lower back. Support article 2000includes backing 2010 in the general shape shown.

FIG. 20B shows the rear surface of support article 2000. Back (or rearor bottom) major surface of backing 2010 is at least partially coatedwith or adjacent to an adhesive 2030 that can adhere the support articleto the user's skin and which, in some embodiments, may also adhere theone or more reinforcing portions 2020 to backing 2010. In the exemplaryembodiment shown, reinforcing portion 2020 is adhered or attached to atleast a portion of the rear (or back or bottom) major surface of backing2010. In this exemplary embodiment, first reinforcing portion 2020 hasthe general shape shown. This includes a linear middle portion 2074 fromwhich extend four linear branches 2076. In this embodiment, the terminalend of each linear branch 2076 includes a second reinforcing portion2022 that has a generally circular, oval, or elliptical shape. Asdescribed above, the second reinforcing portion(s) 2022 can be part ofthe support article during sale and/or manufacturing or can be separatefrom the remainder of the support article under the user applies them toform a single support article. The benefits, advantages, and uses of thesecond reinforcing portions 2076 are described herein.

The lower back support embodiment shown in FIGS. 20A and 20B is merelyexemplary and may be modified in any way described herein and/or obviousto those of skill in the art. For example, any desired number, shape,size, or thickness reinforcing portion(s) may be used. For example, thesupport article may additionally include one or more of third, fourth,firth, etc. reinforcing portions. These can be part of the supportarticle at the time of manufacturing and/or purchase or can be separate.In instances where the second (or third, fourth, etc.) reinforcingportions are separate at the time of purchase, use, or manufacture, theycan be applied by the user separate from the support article. In suchinstances, they may become part of the support article once the userapplies them and they all adhere, attach, or are placed adjacent to oneanother. For purposes of clarity, multiple reinforcing portions (spacedapart or layered on each other) may be used in any of the embodiments orimplementations described herein. Any desired shape, size, or thicknessbacking may be used. Any of the backings, adhesives, and/or reinforcingportions described herein can be used. Any adhesive capable of use onskin can be used, as is discussed in greater detail herein. Thereinforcing portions can be adhesively attached or adhered to thebacking or can be mechanically attached or adhered to the backing, as isdescribed in greater detail herein. The release liner can be in anyshape or size, including in a single or multiple pieces. The releaseliner may extend over the reinforcing portions or may have a cut outaround reinforcing portions. The support article positioning on the bodymay differ.

FIGS. 21A and 21B show an exemplary support article embodiment that canbe used, for example, as a foot arch support article. FIGS. 21A and 21Bare respective front (or top) and rear (or bottom or back) views of anexemplary embodiment of a support article in accordance with theteachings of the present disclosure. FIG. 21A schematically showssupport article 2100 in use on the arch. Support article 2100 includesbacking 2110 in the general shape shown.

FIG. 21B shows the rear surface of support article 2100. Back (or rearor bottom) major surface of backing 2110 is at least partially coatedwith or adjacent to an adhesive 2130 that can adhere the support articleto the user's skin and which, in some embodiments, may also adhere theone or more reinforcing portions 2120 to backing 2110. In the exemplaryembodiment shown, reinforcing portion 2120 is adhered or attached to atleast a portion of the rear (or back or bottom) major surface of backing2110. In this exemplary embodiment, reinforcing portion 2120 has generalshape shown that generally mimics or follows the overall shape of thebacking.

The foot arch support embodiment shown in FIGS. 21A and 21B is merelyexemplary and may be modified in any way described herein and/or obviousto those of skill in the art. For example, any desired number, shape,size, or thickness reinforcing portion(s) may be used. Any desiredshape, size, or thickness backing may be used. Any of the backings,adhesives, and/or reinforcing portions described herein can be used. Anyadhesive capable of use on skin can be used, as is discussed in greaterdetail herein. The reinforcing portions can be adhesively attached oradhered to the backing or can be mechanically attached or adhered to thebacking, as is described in greater detail herein. The release liner canbe in any shape or size, including in a single or multiple pieces. Therelease liner may extend over the reinforcing portions or may have a cutout around reinforcing portions. The support article positioning on thebody may differ.

FIGS. 22A and 22B show an exemplary support article embodiment that canbe used, for example, as a trapezius or shoulder support article. FIGS.22A and 22B are respective front (or top) and rear (or bottom or back)views of an exemplary embodiment of a support article in accordance withthe teachings of the present disclosure. FIG. 22A schematically showssupport article 2200 in use on the trapezius/shoulder. Support article2200 includes backing 2210 in the general shape shown.

FIG. 22B shows the rear surface of support article 2200. Back (or rearor bottom) major surface of backing 2210 is at least partially coatedwith or adjacent to an adhesive 2230 that can adhere the support articleto the user's skin and which, in some embodiments, may also adhere theone or more reinforcing portions 2220 to backing 2210. In the exemplaryembodiment shown, reinforcing portion 2220 is adhered or attached to atleast a portion of the rear (or back or bottom) major surface of backing2210. In this exemplary embodiment, first reinforcing portion 2220 hasthe general shape shown. This includes three linear branches 2276. Inthis embodiment, the terminal end of each linear branch 2276 includes asecond reinforcing portion 2222 that has a generally circular, oval, orelliptical shape. As described above, the second reinforcing portion(s)2222 can be part of the support article during sale and/or manufacturingor can be separate from the remainder of the support article under theuser applies them to form a single support article. The benefits,advantages, and uses of the second reinforcing portions 2222 aredescribed herein.

The trapezius/shoulder support embodiment shown in FIGS. 22A and 22B ismerely exemplary and may be modified in any way described herein and/orobvious to those of skill in the art. For example, any desired number,shape, size, or thickness reinforcing portion(s) may be used. Forexample, the support article may additionally include one or more ofthird, fourth, firth, etc. reinforcing portions. These can be part ofthe support article at the time of manufacturing and/or purchase or canbe separate. In instances where the second (or third, fourth, etc.)reinforcing portions are separate at the time of purchase, use, ormanufacture, they can be applied by the user separate from the supportarticle. In such instances, they may become part of the support articleonce the user applies them and they all adhere, attach, or are placedadjacent to one another. For purposes of clarity, multiple reinforcingportions (spaced apart or layered on each other) may be used in any ofthe embodiments or implementations described herein. Any desired shape,size, or thickness backing may be used. Any of the backings, adhesives,and/or reinforcing portions described herein can be used. Any adhesivecapable of use on skin can be used, as is discussed in greater detailherein. The reinforcing portions can be adhesively attached or adheredto the backing or can be mechanically attached or adhered to thebacking, as is described in greater detail herein. The release liner canbe in any shape or size, including in a single or multiple pieces. Therelease liner may extend over the reinforcing portions or may have a cutout around reinforcing portions. The support article positioning on thebody may differ.

FIGS. 23A and 23B show an exemplary support article embodiment that canbe used, for example, as a heel and/or Achilles tendon support article.FIGS. 23A and 23B are respective front (or top) and rear (or bottom orback) views of an exemplary embodiment of a support article inaccordance with the teachings of the present disclosure. FIG. 23Aschematically shows support article 2300 in use on the arch. Supportarticle 2300 includes backing 2310 in the general y-shape or wishboneshape shown.

FIG. 23B shows the rear surface of support article 2300. Back (or rearor bottom) major surface of backing 2310 is at least partially coatedwith or adjacent to an adhesive 2330 that can adhere the support articleto the user's skin and which, in some embodiments, may also adhere theone or more reinforcing portions 2320 to backing 2310. In the exemplaryembodiment shown, two reinforcing portions 2320 are adhered or attachedto at least a portion of the rear (or back or bottom) major surface ofbacking 2310.

The heel and/or Achilles tendon support embodiment shown in FIGS. 23Aand 23B is merely exemplary and may be modified in any way describedherein and/or obvious to those of skill in the art. For example, anydesired number, shape, size, or thickness reinforcing portion(s) may beused. Any desired shape, size, or thickness backing may be used. Any ofthe backings, adhesives, and/or reinforcing portions described hereincan be used. Any adhesive capable of use on skin can be used, as isdiscussed in greater detail herein. The reinforcing portions can beadhesively attached or adhered to the backing or can be mechanicallyattached or adhered to the backing, as is described in greater detailherein. The release liner can be in any shape or size, including in asingle or multiple pieces. The release liner may extend over thereinforcing portions or may have a cut out around reinforcing portions.The support article positioning on the body may differ.

FIGS. 24A and 24B show an exemplary support article embodiment that canbe used, for example, as a lower back support article. FIGS. 24A and 24Bare respective front (or top) and rear (or bottom or back) views of anexemplary embodiment of a support article in accordance with theteachings of the present disclosure. FIG. 24A schematically showssupport article 2400 in use on the lower back. Support article 2400includes backing 2410 in the shape generally shown.

FIG. 24B shows the rear surface of support article 2400. Back (or rearor bottom) major surface of backing 2410 is at least partially coatedwith or adjacent to an adhesive 2430 that can adhere the support articleto the user's skin and which, in some embodiments, may also adhere theone or more reinforcing portions 2420 to backing 2410. In the exemplaryembodiment shown, there are two reinforcing portions 2420A. 2420Badhered or attached to at least a portion of the rear (or back orbottom) major surface of backing 2410. In this exemplary embodiment,both reinforcing portions 2420A, 2420B have a generally concave shape.Each of reinforcing portions 2420A, 2420B include (optional) secondreinforcing portions 2422 located generally on each terminal end of eachreinforcing portion 2420A, 2420B. As described above, the secondreinforcing portion(s) 2422 can be part of the support article duringsale and/or manufacturing or can be separate from the remainder of thesupport article under the user applies them to form a single supportarticle. The benefits, advantages, and uses of the second reinforcingportions 2476 are described herein.

The lower back support embodiment shown in FIGS. 24A and 24B is merelyexemplary and may be modified in any way described herein and/or obviousto those of skill in the art. For example, any desired number, shape,size, or thickness reinforcing portion(s) may be used. For example, thesupport article may additionally include one or more of third, fourth,firth, etc. reinforcing portions. These can be part of the supportarticle at the time of manufacturing and/or purchase or can be separate.In instances where the second (or third, fourth, etc.) reinforcingportions are separate at the time of purchase, use, or manufacture, theycan be applied by the user separate from the support article. In suchinstances, they may become part of the support article once the userapplies them and they all adhere, attach, or are placed adjacent to oneanother. For purposes of clarity, multiple reinforcing portions (spacedapart or layered on each other) may be used in any of the embodiments orimplementations described herein. Any desired shape, size, or thicknessbacking may be used. Any of the backings, adhesives, and/or reinforcingportions described herein can be used. Any adhesive capable of use onskin can be used, as is discussed in greater detail herein. Thereinforcing portions can be adhesively attached or adhered to thebacking or can be mechanically attached or adhered to the backing, as isdescribed in greater detail herein. The release liner can be in anyshape or size, including in a single or multiple pieces. The releaseliner may extend over the reinforcing portions or may have a cut outaround reinforcing portions. The support article positioning on the bodymay differ.

Backing:

The backing can be any acceptable backing layer. The backing can be asingle layer or multilayer. In some embodiments, the backing layer is anonwoven layer. In some embodiments, the backing is at least one of apolyurethane film, a polyethylene film, a polypropylene film, a PVCfilm, a nonwoven material (e.g., an elastic nonwoven fabric), and/or awoven material. Some commercially available exemplary backings includeDureflex® and Platilon® sold or made by Covestro LLC, South Deerfield,Mass.; 3M™ Tegaderm™ sold or made by 3M Company, Maplewood, Minn.;Sontara® sold or made by Jacob Holm & Sons AG, Basel, Switzerland;HUATAO-020 sold or made by Huatao Group. Shijiazhuang, China; and PA2Bsold or made by Hollingsworth & Vose, East Walpole, Mass.

Some exemplary suitable nonwoven article backings can be formed as meltblown microfiber webs using the apparatus discussed, for example, inWente, Van A., “Superfine Thermoplastic Fibers”, Industrial EngineeringChemistry, Vol. 48, pages 1342-1346. Wente. Van A. et al., “Manufactureof Superfine Organic Fibers”, Report No. 4364 of the Navel ResearchLaboratories, published May 25, 1954, and in U.S. Pat. Nos. 3,849,241;3,825,379, all of which are incorporated in their entirety herein. Thesemicrofine fibers are termed melt blown fibers or blown microfibers (BMF)and are generally substantially continuous and form into a coherent webbetween the exit die orifice and a collecting surface by entanglement ofthe microfibers due in part to the turbulent airstream in which thefibers are entrained. Other conventional melt spinning type processes,such as spunbond processes where the fibers are collected in a web formimmediately upon fiber formation, can also be used to form the nonwovenarticle backing. In some embodiments, the fibers are 100 microns or lessin diameter when formed by melt spinning type processes, preferably 50microns or less. The multicomponent fibers, if formed by the melt blownprocess, can be produced as described in U.S. Pat. No. 5,176,952 (Josephet al); U.S. Pat. No. 5,232,770 (Joseph); U.S. Pat. No. 5,238,733(Joseph et al); U.S. Pat. No. 5,258,220 (Joseph); or U.S. Pat. No.5,248,455 (Joseph et al), each of which is incorporated by referenceherein in its entirety. The multicomponent fiber can also be produced bya spunbond process as are disclosed in U.S. Pat. No. 5,695,868(McCormach); U.S. Pat. No. 5,336,552 (Strack et al) U.S. Pat. No.5,545,464 (Stokes); U.S. Pat. Nos. 5,382,400; 5,512,358 (Shawyer et al);or U.S. Pat. No. 5,498,463 (McDowall et al), each of which isincorporated by reference herein in its entirety.

In some embodiments, the backing layer includes conjugate multicomponentmelt spun fibers. For example, the backing layer can be any of thebacking layers described in, for example, U.S. Pat. No. 6,107,219(Joseph), the entirety of which is incorporated by reference herein. Theconjugate multicomponent melt spun fibers used to form the nonwovenbacking can be, for example, polymeric. In some embodiments, the fibersare organic polymeric materials. Some exemplary suitable materials foruse in forming conjugate multicomponent fibers include polyolefins,polyesters, polyalkylenes, polyamides, polystyrenes, polyarylsulfones,polydienes or polyurethanes. These materials are preferably extensibleor slightly elastomeric, but could be elastomeric. In some embodiments,extensible or slightly elastomeric polyurethanes may be preferred (e.g.,“MORTHANE” PS 440-200 resin available from Morton Thiokol Corp; alsoknown as “IROGRAN” PS440-200 from Huntsman); and polyolefins such aspolyethylenes, polypropylenes, ethylene-propylene copolymers,ethylene/vinyl acetate copolymers, or metallocene-type polyethyleneshaving a density of greater than 0.87 grams/cm³. Other suitableelastomeric materials include metallocene-type polyethylene copolymers(apparent density less than 0.87 grams/cm³); polyolefin elastomers(e.g., ethylene/propylene/diene elastomers); A-B block copolymers, asdescribed above, having A blocks formed of poly (vinyl arenes) such aspolystyrene and B blocks formed of conjugated dienes such as isoprene,butadiene, or hydrogenated versions thereof (e.g., “KRATON” elastomersavailable from Shell Chemical Co., now known as Kraton Corporation):polyetheresters (such as “ARNITEL”, available from DSM.); or polyetherblock amides (such as “PEBAX”, available from Atochem Co.). Blends ofelastomers, blends of nonelastomers or blends of both elastomers andnonelastomers can also be used.

In some embodiments, the conjugate multicomponent melt spun fibershaving a diameter of no greater than about 10 microns. In someembodiments, the conjugate multicomponent melt spun fibers have adiameter up to about 50 microns or more (these are typically fibersprepared using a melt-blown process). In some embodiments, fibers havinga diameter of up to about 100 microns can be prepared (these aretypically fibers prepared using a spun bond process).

In some embodiments, the nonwoven backing includes additional fibers,such as, for example, other melt spun fibers, staple fibers (includinginorganic and organic fibers, such as thermoplastic fibers, carbonfibers, glass fibers, or mineral fibers), organic binder fibers, and/orfibers of different polymers. Alternatively, other polymer materials canbe simultaneously melt processed with the multicomponent fibers of thepresent invention to form webs containing more than one type of meltprocessed fiber, preferably, melt blown microfiber. Webs having morethan one type of fiber are referred to herein as having commingledconstructions. In commingled constructions, the various types of fiberscan be intimately mixed forming a substantially uniform cross-section,or they can be in separate layers. The web properties can be varied bythe number of different fibers used, the number of layers or regionsemployed, and the layer or region arrangement. Other materials, such assurfactants or binders can also be incorporated into the web before,during, or after its collection, such as by the use of a spray jet.

In some embodiments, the fibers forming the nonwoven article backing areintimately entangled each with the other in the form of a coherentbreathable fibrous nonwoven article backing.

In some embodiments, the backing layer is breathable and/or porous. Insome embodiments, the backing layer is highly breathable and/or porous,making the support article comfortable to wear and/or to minimize orprevent itching, irritation, or undesirable skin reactions. In someembodiments, the backing layer allows for moisture release. The moreporous the backing layer, the better the backing layer will releasemoisture caused by sweating or being worn in water or humidenvironments. In some embodiments, the backing layer has a breathabilityand/porosity of between about 3 and about 12 mm H₂O measured using thepressure drop test. In some embodiments, the backing layer has abreathability and/porosity of between about 4 and about 12 mm H₂Omeasured using the pressure drop test. In some embodiments, the backinglayer has a breathability and/porosity of at least about 3 mm H₂Omeasured using the pressure drop test. In some embodiments, the backinglayer has a breathability of at least about 5 mm H₂O measured using thepressure drop test. As used herein, the pressure drop test involvescutting a 5.25 inch circle from a MBPU web; placing the sample into apenetrometer (such as, for example, Model #8810 AFT Penetrometer with a4.5 inch elastomeric chuck) with the airflow at 85 liters per minute;the sample should be set in the penetrometer collector (smooth) sidedown onto the lower flat chuck of the test equipment and securing it inplace with the upper chuck; and measuring the recording the pressuredrop in mm H₂O.

In some embodiments, the backing has a weight of between about 25 gsm toabout 300 gsm. In some embodiments, the backing has a weight of betweenabout 120 gsm to about 160 gsm.

In some embodiments, the backing has a cross-directional tensilestrength of between about 4 lbf (17.8 N) and about 9 lbf (40.0 N). Insome embodiments, the backing has a cross-directional tensile strengthof between about 5 lbf (22.2 N) and about 8 lbf (35.6 N). In someembodiments, the backing has a cross-directional tensile strength ofbetween about 6 lbf (26.7 N) and about 7 lbf (31.1 N). In someembodiments, the backing has a cross-directional tensile strength ofgreater than about 4 lbf (17.8 N). In some embodiments, the backing hasa cross-directional tensile strength of greater than about 5 lbf (22.2N). In some embodiments, the backing has a cross-directional tensilestrength of less than about 9 lbf (40.0 N). In some embodiments, thebacking has a cross-directional tensile strength of less than about 8lbf (35.6 N).

In some embodiments, the backing has a machine-directional tensilestrength of between about 5 lbf (22.2 N) and about 10 lbf (44.5 N). Insome embodiments, the backing has a machine-directional tensile strengthof between about 6 lbf (26.7 N) and about 9 lbf (40.0 N). In someembodiments, the backing has a machine-directional tensile strength ofbetween about 7 lbf (31.1 N) and about 8 lbf (35.6 N). In someembodiments, the backing has a machine-directional tensile strength ofgreater than about 5 lbf (22.2 N). In some embodiments, the backing hasa machine-directional tensile strength of greater than about 6 lbf (26.7N). In some embodiments, the backing has a machine-directional tensilestrength of less than about 10 lbf (44.5 N). In some embodiments, thebacking has a machine-directional tensile strength of less than about 9lbf (40.0 N). Tensile strength was measured as described herein.

In some embodiments, the backing has a cross-directional elongation atbreak of about 900%. In some embodiments, the backing has across-directional elongation at break of between about 600% and about900%, or about 600% and about 800%. Elongation at break was measured asdescribed herein.

In some embodiments, the backing has a machine-directional elongation atbreak of about 1000%. In some embodiments, the backing has amachine-directional elongation of between about 350% and about 1000%, orbetween about 450-550%. Elongation was measured as described herein.

The backing can have any suitable thickness. In some embodiments, thebacking has a thickness of about 0.01 cm (3.94 mil) to about 1 cm (393mil). In some embodiments, the backing has a thickness of at least 0.01cm (3.94 mil). In some embodiments, the backing has a thickness of nogreater than about 0.5 cm (197 mil), or about 0.4 cm (157 mil), or about0.3 cm (118 mil), or about 0.2 cm (79 mil), or about 0.1 cm (39 mil). Insome embodiments, the backing has a thickness of less than about 1 mil(0.0025 cm), or less than 0.75 mil (0.0019 cm), or less than 0.5 mil(0.0127 cm).

Adhesive

Adhesives used in the present disclosure can include at least twoadhesives: (1) the adhesive used to adhere the support article to theuser (located on the rear (or bottom or back) side of the backing); and(2) the adhesive (where used) used to adhere the reinforcing portion(s)to the rear (or bottom or back) side of the backing. In someembodiments, these two adhesives are the same. In some embodiments,these two adhesives differ. In some embodiments, the reinforcingportions are attached to the backing using non-adhesive means, in whichcase the second adhesive would not be present. Some exemplarynon-adhesive means include lamination, ultrasonic welding, hook andloop, etc. Each of these adhesives will be described in greater detailbelow.

Adhesives Used to Adhere the Backing or Support Article to the User

Any adhesive capable of use on skin may be used on the rear (or back orbottom) side of the backing to adhere the backing to the user. Selectionof a desired adhesive to adhere the backing to the user may be based onvarious factors including, for example, the region of the body on whichthe support article is meant to be used, the skin sensitivity profile ofthe end user, etc. Some exemplary adhesives include those described in,for example, U.S. Pat. No. 6,107,219 (Joseph et al.), U.S. Pat. No.6,703,120 (Ko et al.); U.S. Pat. No. 7,407,709 (Zhou et al.); U.S. Pat.No. 7,807,268 (Zhou et al.); U.S. Pat. No. 9,359,529 (Liu et al.); U.S.Pat. No. 8,541,481 (Determan et al.); U.S. Pat. No. 9,017,771 (Determanet al.); U.S. Pat. No. 6,730,397 (Melancon et al.); U.S. Pat. No.8,822,559 (Zoller et al.); and U.S. Pat. No. 8,822,560 (Seth et al.) andU.S. Patent Publication Nos. 2011-0206924 (Liu et al.), 2014-0220843(Liu et al.), 2015-0165087 (Fung et al.), 2015-0376345 (Liu et al.),2017/081573 (Kipke et al.), 2015/299542 (Determan et al.), 2013/040073(Pett et al.), and 2015/259495 (Liu et al.), all of which areincorporated by reference in their entirety herein. In some embodiments,the adhesive also preferably has good release from a liner that will beused on the rear (or back or bottom) major surface of the backing.

In some embodiments, the adhesive is a pressure-sensitive adhesive(PSA). Some exemplary suitable classes of pressure-sensitive adhesivesinclude polyacrylate adhesives, polyalphaolefin adhesives, polyvinylacrylates, rubber resin adhesives, silicone adhesives,polydiorganosiloxane polyurea compolymers, mixtures or the like. Someexemplary suitable rubber resin adhesives include those formed using atackified elastomer where a preferred elastomer is an A-B type blockcopolymer wherein the A blocks and B blocks are configured in linear(e.g. diblock or triblock copolymer), radial or star configurations. TheA block can be formed of a mono-alkenylarene, preferably a polystyreneblock having a molecular weight between 4000 and 50,000, preferablybetween 7000 and 30,000. The A block content is preferably about 10 to50 weight percent, preferably about 10 to 30 weight percent of the blockcopolymer. Other exemplary suitable A blocks may be formed fromalpha-methylstyrene, t-butyl-styrene and other ring alkylated styrenes,as well as mixtures thereof. The B block may be formed of an elastomericconjugated diene, generally polyisoprene, polybutadiene or copolymersthereof having an average molecular weight from about 5000 to about500,000, preferably from about 50,000 to about 200.000. The B blockdienes can also be hydrogenated. In some embodiments, the B blockcontent is generally 90 to 50 percent, preferably 90 to 70 percent byweight.

The pressure-sensitive adhesives or adhesive fibers can be mixed withparticulates, such as sorbent particulate material, fumed silica, carbonblack, glass beads, glass bubbles, clay particles, metal particles, andthe like. Tackifiers (solid or liquid), plasticizers, colorants, endblock resins, oils, cross-linkers, etc. may be included. Fillers,plasticizers, and other property modifiers, such as flow modifiers,dyes, pigments, flame retardants, stabilizers, antioxidants,compatibilizers, antimicrobial agents, electrical conductors, andthermal conductors, may be incorporated in the pressure-sensitiveadhesive composition.

In some embodiments, the adhesive layer is applied to the entire rear(or back or bottom) major surface of the backing. In some embodiments,the adhesive does not cover the entire rear (or back or bottom) majorsurface of the backing. In some embodiments, the adhesive covers atleast 50% of the backing, or at least 75%, or at least 90%, or at least95% of the total surface of the rear (or back or bottom) major surfaceof the backing. In some embodiments, the adhesive is pattern coated ontothe rear (or back or bottom) major surface of the backing. In someembodiments, the adhesive is coated on (for example, blowing on or rollcoating), sprayed on, or laminated to the backing.

In some embodiments, the backing and adhesive form a conjugatemulticomponent system, as described in, for example, U.S. Pat. No.6,107,219 (Joseph et al.), incorporated by reference herein in itsentirety. In such embodiments, the adhesive component layer or regionand non-adhesive component layer or region are present in separatedistinct regions in a conjugate multicomponent fiber. For example,multicomponent fiber layers or regions can be in the form of two, ormore, overlaying layered fibers, sheath-core or concentric layered fiberarrangements or in “island in the sea” type fiber layer structures. Onecomponent region would comprise the adhesive component layer or regionand a second component region would comprise the non-adhesive materiallayer or region. Generally the adhesive fiber component region willprovide at least a portion of the exposed outer surface of themulticomponent conjugate fiber. Preferably, the individual components ofthe multicomponent conjugate fibers will be present substantiallycontinuously along the fiber length in discreet zones, which zonespreferably extend along the entire length of the fibers.

In some embodiments, the backing and adhesive combination is breathableand/or porous. In some embodiments, the backing and adhesive combinationis highly breathable and/or porous, making the support articlecomfortable to wear and/or to minimize or prevent itching, irritation,or undesirable skin reactions. In some embodiments, the backing andadhesive combination allows for moisture release. The more porous and/orbreathable the backing and adhesive combination, the better the supportarticle will release moisture caused by sweating or being worn in wateror humid environments. In some embodiments, the backing and adhesivecombination has a breathability and/or porosity of between about 6 andabout 20 mm H₂O measured using the pressure drop test. In someembodiments, the backing layer has a breathability and/or porosity ofbetween about 10 and about 20 mm H₂O measured using the pressure droptest. In some embodiments, the backing+adhesive combination has abreathability and/or porosity of at least about 6 mm H₂O measured usingthe pressure drop test. In some embodiments, the backing+adhesivecombination has a breathability of at least about 10 mm H₂O measuredusing the pressure drop test. The breathability and/or porosity wasmeasured using the pressure drop test described above.

In some embodiments, the backing and adhesive combination has across-directional tensile strength of between about 3 lbf (13.3 N) andabout 11 lbf (48.9 N). In some embodiments, the backing and adhesivecombination has a cross-directional tensile strength of between about 4and about 10 lbf (44.5 N). In some embodiments, the backing and adhesivecombination has a cross-directional tensile strength of greater thanabout 3 lbf (13.3 N). Tensile strength can be measured as describedabove.

In some embodiments, the backing and adhesive combination has amachine-directional tensile strength of between about 4 lbf (17.8 N) andabout 15 lbf (66.7 N). In some embodiments, the backing and adhesivecombination has a machine-directional tensile strength of between about5 lbf (22.2 N) and about 13 lbf (57.8 N). In some embodiments, thebacking and adhesive combination has a machine-directional tensilestrength of greater than about 4 lbf (17.8 N). In some embodiments, thebacking and adhesive combination has a machine-directional tensilestrength of greater than about 6 lbf (26.7 N). In some embodiments, thebacking and adhesive combination has a machine-directional tensilestrength of less than about 15 lbf (66.7 N). In some embodiments, thebacking and adhesive combination has a machine-directional tensilestrength of less than about 12 lbf (53.4 N). Tensile strength can bemeasured as described above.

In some embodiments, the backing and adhesive combination has across-directional elongation at break of about 900%. In someembodiments, the backing and adhesive combination has across-directional elongation at break of between about 600% and about900%, or about 600% and about 800%. Elongation at break was measured asdescribed herein.

In some embodiments, the backing and adhesive combination has amachine-directional elongation at break of about 1000%. In someembodiments, the backing and adhesive combination has amachine-directional elongation of between about 350° % and about 1000%,or between about 450-550%. Elongation was measured as described herein.Elongation at break was measured as described herein.

Adhesive Used to Adhere the Reinforcing Portion(s) to the Backing:

Any of the adhesives described above or herein can be used to adhere thereinforcing portion(s) to the backing. Where a different adhesive isused to adhere the reinforcing portion(s) to the backing, the adhesivecan be any desired adhesive and need not be capable of use on skin sinceit would not necessarily be used directly on human skin. Additionally oralternatively, the adhesive need not have the porosity or breathabilitydescribed above and/or herein. Additionally or alternatively, theadhesive need not have the same release properties from a linerdescribed above and/or herein, since the adhesive may not be in contactwith the liner. In some embodiments, the adhesive used to adhere thereinforcing portion(s) to the backing may adhere more strongly than theadhesive used to adhere the support article to the user. Some exemplarysuitable classes of pressure-sensitive adhesives include polyacrylateadhesives, polyalphaolefin adhesives, polyvinyl acrylates, rubber resinadhesives, silicone adhesives, polydiorganosiloxane polyureacompolymers, mixtures or the like.

Reinforcing Portion(s)

The reinforcing portion(s) can have a size, shape, thickness, material,etc. that allow the reinforcing portion(s) to be rigid enough to providesupport, compression, and/or pain relief, conformable enough to permitease of movement and comfort, and/or thin enough to provide a discreetmaterial whose presence is not readily detectable under clothing. Insome embodiments, it is preferred that the reinforcing portion not snapor break during use, which often happens with some existing braces thatinclude plastic reinforcement materials. Any reinforcing portion thatprovides these qualities may be used. In some embodiments, the shapeand/or size of the reinforcing portion is tailored for use on a specificarea or region of the body. Exemplary reinforcing portion shapesinclude, but are not limited to, almond shapes, ellipses, ovals,circles, hemispheres, quadrilaterals, hexagons, heptagons, any shapesshown in the Figures of the present disclosure, etc. In someembodiments, the reinforcing portion(s) do not have adhesive on the userskin-facing major surface. In some embodiments, the reinforcingportion(s) have adhesive on the user skin-facing major surface.

In some embodiments, the reinforcing portion is positioned between thebacking and the user's skin, when the support article is in use. In someembodiments, the reinforcing portion is on the front (or top) majorsurface of the backing instead of being between the backing and theuser's skin. For purposes of clarity, none of the figures show theseembodiments, but any of the embodiments shown or described herein caninclude the reinforcing portion on the top (front) major surface of thebacking.

In some embodiments, the reinforcing portion is a foam layer. In someembodiments, the reinforcing portion is a shaped memory foam layer. Insome embodiments, the reinforcing portion is a shaped memory polymersuch as, for example, those described in U.S. Patent Publication No.2010/155998 (Rule et al.), the entirety of which is incorporated herein.In some embodiments, the foam layer includes at least one ofpolyethylene (“PE”), cross-linked PE, polyurethane, reticulated (opencell) foam, unreticulated (closed cell) foam, neoprene, melamine, vinylnitrile, PET, XPS (extruded 1-polystyrene), EPS (expanded polystyrene),phenolic, EPP (expanded polypropylene), and EPE (expanded polyethylene).In some embodiments, the reinforcing portion includes a foam layer asdescribed in U.S. Provisional Patent Application No. 62/429,401,assigned to the present assignee, the entirety of which is incorporatedherein.

In some embodiments, the reinforcing portion includes a multilayerconstruction. In some embodiments, the multilayer construction includesan adhesive layer between first and second foam layers and thatconstruction between first and second skin layers. In other words, theoutermost layer is a first skin layer adjacent to a first foam layeradjacent to an adhesive layer adjacent to a second foam layer adjacentto an outer second skin layer. In some embodiments, one or more of thefoam layers include microspheres or expandable microspheres. In someembodiments, the microspheres are at least partially embedded in theadhesive layer. In some embodiments, at least one of the skin layers issubstantially free of microspheres. In some embodiments, both skinlayers are substantially free of microspheres. In some embodiments, theexpandable microspheres in one or more of the foam layer arehomogenously distributed throughout the foam layer. In some embodiments,the expandable microspheres in one or both of the foam layers arepresent in a range of between about 4 wt % to about 35 wt % or about 5wt % to about 25 wt %, based on the total weight of the respective firstand second pluralities of expandable microspheres.

Where present, the microspheres may be compressible and retain theirspherical shape and integrity after compression, resulting in thereinforcing portion being very resilient and having a high restorationforce. During use/wear of the support article, the reinforcingportion(s) readily conform to user movement but continue to providesupport because the expanded spheres are resilient and provide strengthand support before, during, and after compression. The force exerted torestore the support article is greater than a traditional open cell foambecause the microspheres are compressed and have a higher restorationforce vs. traditional foam. The microsphere foam is unique in that themore microspheres are added the higher the restoration force due to theincrease in number of microspheres present. In a traditional open orclosed cell foam a decrease in density typically results in a decreasedrestoration force because there is a reduction in the amount of polymerpresent. In the microsphere foam the shell of the microspheres providesa large part of the restoration force—in a traditional foam the polymeritself provides the restoration force—lower density traditionalfoam=less polymer=lower restoration force.

In some embodiments, the expandable microsphere loading is between about3% and about 50%. In some embodiments, the microsphere loading isgreater than about 3% or greater than about 5%, or greater than about7%. In some embodiments, the microsphere loading is less than about 50%or less than about 45%, or less than about 40%, or less than about 35%,or less than about 25%, or less than about 15%, or less than about 10%.This resulted in a lightweight, conformable (compressible) foamstructure with reduced density loading.

A schematic cross section of an exemplary construction as describedabove is shown in FIG. 25 in which reinforcing portion 2500 includes anadhesive layer 2510 whose first and second major surfaces 2512, 2514 areeach adjacent to first and second foam layers 2520, 2522. First foamlayer 2520 is adjacent to a first skin layer 2540, and second foam layer2522 is adjacent to a second skin layer 2550. First and second skinlayers 2540 and 2550 give reinforcing portion 2500 rigidity, while firstand second foam layers 2520, 2522 provide softness, resiliency, andconformability. Microspheres 1560 are in adhesive layer 2510 and one orboth of first and second foam layers 2520, 2522. More information abouteach layer of these embodiments of the reinforcing portion is below.

Skin Layer(s):

Exemplary skin layers include, for example, at least one of apolyethylene, a polypropylene, a polyurethane, a polylactic acid,ethylene and methacrylate ester copolymer, or copolymers thereof. Insome embodiments, at least one of the skin layers includes at least oneof a polyolefinic material (e.g., polypropylene and/or polyethylene),modified polyolefinic material, polyvinyl chloride, polycarbonate,polystyrene, polyester (including co-polyester), polylactide,polyvinylidene fluoride, (meth)acrylic (e.g., polymethyl methacrylate),urethane, acrylic urethane, ethylene vinyl acetate copolymer,acrylate-modified ethylene vinyl acetate polymer, ethylene acrylic acidcopolymers, nylon, engineering polymer (e.g., a polyketone and/orpolymethylpentane), or elastomer (e.g., natural rubber, syntheticrubber, styrene block copolymer containing isoprene, butadiene, orethylene (butylene) blocks; metallocene-catalyzed polyolefin,polyurethanes; or polydiorganosiloxane). First and second skin layerscan be the same or different in composition, density, thickness, etc.

In some embodiments, the use of skins to increase stiffness is highlyeffective due to the fact that the stiffness of a material increaseswith the cube of the thickness. In some embodiments, strategicallyplacing the skins on the outer portion of the foam layers provides highrelative stiffness in a thin layer while retaining the compression andresilience provided by a foam. If the entire structure were foam withoutskins, the thickness of the total reinforcing portions could besignificantly greater. In some embodiments, combining a resilient,compressible foam with non-foamed (or minimally foamed) skin layer(s)results in a thinner reinforcing portion than of comparable modulus vs.that of a monolithic foamed layer. In some embodiments, the skins alsoprovide tear strength to the foamed layer.

Foam Layer(s):

Exemplary foam layers include, for example, at least one of apolyethylene, a polyurethane, a polylactic acid, a polypropylene, anethylene and methacrylate ester copolymer, or copolymers thereof. Firstand second foam layers can be the same or different in composition,density, thickness, etc.

Adhesive Layer:

The adhesive can be any one of a number of pressure sensitive adhesivesor non-pressure sensitive adhesive. Examples of suitable pressuresensitive adhesives include a natural rubber-based adhesive, a syntheticrubber based adhesive, a styrene block copolymer-based adhesive, apolyvinyl ether-based adhesive, a poly(methyl acrylate)-based adhesive,a polyolefin-based adhesive, or a silicone-based adhesive. As usedherein, an adhesive that is “based” on a particular component means thatthe adhesive includes at least 50 wt. % of the particular component,based on the total weight of the adhesive. An exemplary adhesive isavailable under the designated trade designation “KRATON MD6748” fromPolyOne.

Suitable non-pressure sensitive adhesives include those that “self-bond”or “block” at the temperature at which the polymeric multilayer materialis extruded. Examples of suitable non-pressure sensitive adhesivesinclude very low density polyethylene resins or ethylene copolymerresins with high comonomer content such as a high vinyl acetatecontaining ethylene vinyl acetate resin.

In some embodiments, the one or more reinforcing portions have a Shore Adurometer hardness of between about 10 and about 100. In someembodiments, the one or more reinforcing portions have a Shore Adurometer hardness of at least about 10, or at least about 20, or atleast about 30, or at least about 40, or at least about 50. In someembodiments, the one or more reinforcing portions have a Shore Adurometer hardness of less than about 100, or less than about 90, orless than about 80. In some embodiments, the one or more reinforcingportions have a Shore A durometer hardness of between about 50 and about80. Shore A durometer hardness can be measured as described Shore Adurometer hardness can measured according to ASTM D2240 (2000) usingtesting equipment commercially obtained as “MODEL #8 SHORE A AND MODEL#9 SHORE D” from Pacific Transducer Corp (PTC Instruments), Los Angeles,Calif.

In some embodiments, the one or more reinforcing portions have a Shore Ddurometer hardness of between about 10 and about 60. In someembodiments, the one or more reinforcing portions have a Shore Ddurometer hardness of at least about 10, or at least about 20, or atleast about 30. In some embodiments, the one or more reinforcingportions have a Shore D durometer hardness of less than about 60, orless than about 50. In some embodiments, the one or more reinforcingportions have a Shore D durometer hardness of between about 30 and about50. Shore D durometer hardness can measured according to ASTM D2240(2000) using testing equipment commercially obtained as “MODEL #8 SHOREA AND MODEL #9 SHORE D” from Pacific Transducer Corp (PTC Instruments),Los Angeles. Calif.

In some embodiments, the reinforcing portion(s) has a cross-directionaltensile strength of between about 13 lbf (57.8 N) and about 28 lbf(129.0 N). In some embodiments, the reinforcing portion(s) has across-directional tensile strength of greater than about 13 lbf (57.8 N)or greater than about 15 lbf (66.7 N). In some embodiments, thereinforcing portion(s) has a cross-directional tensile strength of lessthan about 28 lbf (129.0 N) or less than about 25 lbf (111.2 N). Tensilestrength is measured as described herein.

In some embodiments, the reinforcing portion(s) has amachine-directional tensile strength of between about 16 lbf (71.2 N)and about 31 lbf (137.9 N). In some embodiments, the reinforcingportion(s) has a machine-directional tensile strength of between about18 lbf (80.1 N) and about 28 lbf (124.6 N). In some embodiments, thereinforcing portion(s) has a machine-directional tensile strength ofgreater than about 16 lbf (71.2 N), or greater than about 20 lbf (89.0N). In some embodiments, the reinforcing portion(s) has amachine-directional tensile strength of less than about 31 lbf (137.9 N)or less than about 28 lbf (124.6 N). Tensile strength is measured asdescribed herein.

In some embodiments, the reinforcing portion is relatively thin or lowprofile compared to a brace. In some embodiments, the reinforcingportion has a thickness of less than 2 cm (787 mil), or less than 1.5 cm(591 mil), or less than 1 cm (394 mil), or less than 0.5 cm (197 mil),or less than 0.25 cm (98 mil). In some embodiments, the reinforcingportion is 100 mil (0.254 cm), or less than 90 mil (0.229 cm), or lessthan 80 mil (0.203 cm), or less than 70 mil (0.178 cm), or less than 60mil (0.152 cm), or less than 50 mil (0.127 cm), or less than 40 mil(0.102 cm), or less than 30 mil (0.076 cm), or less than 20 mil (0.051cm). In some embodiments, the reinforcing portion has a thickness of atleast 20 mil (0.051 cm), at least 30 mil (0.076 cm), or at least 50 mil(0.127 cm). In some embodiments, the reinforcing portion has a thicknessof between about 0.025 cm (9.8 mil) and about 0.155 cm (61 mil).

In some embodiments, the reinforcing portion has a density of betweenabout 0.20 g/cm³ to about 0.60 g/cm³, or in some embodiments, 0.25 g/cm³to 0.4 g/cm³.

In some embodiments, the reinforcing portion(s) is generallynon-elastic. In some embodiments, the reinforcing portion(s) have anelongation at break of between about 10% and about 50%, or between 15%and about 25%.

In some embodiments, the reinforcing portion(s) are relativelynon-compressible in one or both of the X and Y directions while beingmore compressible in the Z direction.

In some embodiments, the reinforcing portion(s) are relativelynon-absorbent. A reinforcing portion is considered relativelynon-absorbent if, after submersion of a 10 gram sample of thereinforcing portion in water at room temperature for 24 hours followedby removing any visible traces of water from the exterior surface of thesample with a tissue, the mass of the sample increases by less than 20%by weight. In some embodiments the mass of such a sample may increase byless than 10% by weight, less 5% by weight, or even less than 1% byweight.

In some embodiments, the reinforcing portion covers at least 10% of thetotal surface area of the backing, or at least 15%, or at least 20%. Insome embodiments, the reinforcing portion covers no greater than 75% ofthe total surface area of the backing, or no greater than 70%, or nogreater than 60%.

Release Liner

Some embodiments of the present disclosure also include a release liner.Commercially available release liners that can be used include, forexample, Polyslik®, PrimeLiner®, Film Plus®, or Lopasil® from Loparex,Cary, N.C.; and CF2 from The Griffin Network, Fallsington, Pa.

Support Article:

In some embodiments, the support article is a patch, cove, sheet, orstrip. In some embodiments, the support article is water resistant. Insome embodiments, the support article can be worn for multiple days. Insome embodiments, the support article can be worn for up to three (3)days. In some embodiments, the support article will not come off whenexposed to humid environments or activities including, for example, inthe shower, in humid environments, during exposure to sweat and/or whileswimming. In some embodiments, the support article is easy to applyand/or easy to remove. In some embodiments, the support article providescompression.

In some embodiments, the support article is at least some of lightweightand/or comfortable to wear. In some embodiments, the support article hasa weight of between about 20 gsm and about 500 gsm. In some embodiments,the support article has a weight of between about 30 gsm and about 300gsm).

In some embodiments, the support article and/or the reinforcing portionof the support article is conformable. In some embodiments, the supportarticle and/or the reinforcing portion(s) of the support article have aconformability of less than 13 inches (33.0 cm). In some embodiments,the support articles and/or reinforcing portion(s) thereof have aconformability of greater than about 8 inches (20.2 cm). Conformabilitycan be measured as is described herein.

In some embodiments, the support article is low profile. In someembodiments, the entire support article (including the backing,adhesive, and reinforcing portion(s)) has a thickness of between about10 mil (0.025 cm) and about 500 mil (1.27 cm).

In some embodiments, the support article includes at least one of ahot/cold formulation and/or a pain-reducing medication (e.g., lidocainc)as part of the support article. In some embodiments, the support articlefurther includes a medicament. In some embodiments, the medicament isone of pain-reducing agent and/or an agent that provides for heating orcooling relative to body temperature (or the sensation of heating orcooling relative to body temperature). In some embodiments, themedicament, hot/cold formulation, and/or a pain-reducing medication isapplied to the reinforcing portion and/or to the adhesive that holds thebacking adjacent to the user's skin. In such embodiments, it may bedesirable that the reinforcing portion has minimal porosity and/orbreathability to ensure that the hot/cold formulation and/or apain-reducing medication only contacts the affected area of the user.

In some embodiments, the support article (or a portion thereof, such asthe reinforcing portion) includes only a single plane of symmetry in themajor surface. In some embodiments, the support article (or a portionthereof, such as a reinforcing portion) has rounded perimeters withoutstraight regions and/or corners.

In some embodiments, the support article has a compression of at least40 mm Hg, or at least 41 mm Hg, or in some embodiments, 42 mm Hg.

The following examples describe some exemplary constructions of variousembodiments of the support articles and methods of making the supportarticles described in the present application. The following examplesdescribe some exemplary constructions and methods of constructingvarious embodiments within the scope of the present application. Thefollowing examples are intended to be illustrative, but are not intendedto limit the scope of the present application.

EXAMPLES

All parts, percentages, ratios, etc. in the examples and the rest of thespecification are by weight unless noted otherwise. Solvents and otherreagents used were obtained from Sigma-Aldrich Chemical Company;Milwaukee, Wis., unless otherwise noted. The following abbreviations areused: cm=centimeters; mm=millimeters; in =inch; m=meters;RPM=revolutions per minute; kg=kilograms; oz=ounces; lb=pounds;Pa=Pascals; min=minutes; hr=hours; gsm=grams per square meter (g/m²);DW=downweb (or alternatively MD=machine direction); CW=crossweb;lbf=pound-force; and N=Newton. The terms “weight %”, “% by weight”, and“wt %” are used interchangeably.

Test Methods

Tensile and Elongation Test

Tensile testing and percent elongation tests were performed using acommercially available tensile tester (obtained under the tradedesignation “ZWICK” from Zwick USA, Kennesaw, Ga.). Tensile and percentelongation testing was performed in the downweb (machine) direction (DW)and in the crossweb (transverse) direction (CW) for all test specimens.Test specimens were cut to be 1 inch (2.54 cm) in width (or in theinstance of certain commercially available tapes obtained in 1 inchwidths, such tapes were used directly, with the 1 inch width as thecrossweb direction). Except where noted, the gauge length was 2 inches(5.08 cm) for downweb testing and 1 inch (2.54 cm) for crossweb testing.A 200 N load cell was used. Depending on the value measured (e.g.,downweb or crossweb tensile strength) clamps were attached to downwebends or crossweb ends of the specimen as appropriate. Crosshead speedwas 10 inches/min (25.4 cm/min). For both downweb and crosswebspecimens, the maximum force achieved during the test (i.e., tensilestrength at break), and the strain at the force maximum (i.e., percentelongation at break), was recorded. Test specimens were tested intriplicate in each of the two principal directions and the resultsaveraged for each of the two principal directions.

Hardness Test

The Shore Durometer Hardness Test (ASTM D-2240 (2000)) was used tomeasure hardness of foamed specimens (i.e., reinforcing portions). Usingtesting equipment commercially obtained as “MODEL #8 SHORE A AND MODEL#9 SHORE D” from Pacific Transducer Corp (PTC Instruments), Los Angeles,Calif.

Both Shore A and Shore D hardness were measured. Each Shore tester(SHORE A and SHORE D) was calibrated. To calibrate each tester, a dialon a gauge of each tester was moved to a zero position. From there aprobe of each tester was pressed to a surface of a known hardness. TheSHORE A tester was considered calibrated if the gauge read 55 and theSHORE D tester considered calibrated if the gauge read 28.

For each specimen, a 1 inch (2.54 cm) square was cut, and the specimenplaced on a hard benchtop surface. The specimens were flattened on thesurface and a probe of the respective testers was positioned over thespecimen. The probe of the instrument was pressed to the specimen, andthe equipment provided a readout on the gauge. In each instance, fivetest specimens were tested and the readouts were averaged. According tosection 9.3 within test method D-2240, durometer readings below 20 orabove 90 are not considered reliable. By this criterion, some of thetest specimens were “too soft.”

Density Test

A pycnometer was used to measure the density of each foamed specimen(i.e., reinforcing portion). The buoyancy force was measured accordingto ASTM D3575-14 (2014) (“Suffix W-test method B), using a pycnometer(obtained under the trade designation “DELTA RANGE” (Model AG204) fromMettler-Toledo, LLC, Columbus, Ohio). The density was then calculatedusing Archimedes' principal. That is, specimens were cut from the foamfilm and first weighed dry (m_(dry)). The specimens were then placedunderwater (de-ionized water) to measure the buoyant force (m_(buoyant))on the pycnometer. Using the formula below, and knowing the density ofwater is 1 g/cm³, the density of the foamed specimen was calculated.

$\rho_{foam} = {\rho_{water}\left( \frac{m_{dry}}{m_{dry} - m_{buoyant}} \right)}$

Test specimens were tested in triplicate and the results averaged.

Conformability Test

Conformability of foamed specimens (i.e., reinforcing portions) wasevaluated as follows. Rectangular test strip specimens 1 inch (2.54 cm)in width and 13 inches (33.02 cm) in length were cut from the foamedmaterial to be tested. The test strip specimens were cut so that thelength of the rectangular shaped specimen was in the downweb direction.Where the cut test strip specimens displayed initial curvature, thespecimens were flattened by either allowing them to relax on a hard,flat surface for 1 day or by hand manipulation (e.g., by running afinger down the length of the specimen putting slight pressure oppositethe curve). The major face of the flattened specimen was then drapedover a 26-inch (66.04 cm) circumference heat-capable cylindrical roll ofa commercially available laminator (Orca III Laminator available fromGBC Pro-Tech. De Forest, Wis.), such that the specimen extended 50% ofthe circumference of the heat-capable roll (i.e., orthogonal to thelength of the roll). The specimen was held in place by taping the endsof the specimen to the heat-capable roll with masking tape. In instanceswhere the roll was heated, the roll was allowed to stabilize at thedesired temperature prior to applying the specimen on the roll, andafter applying the specimen to the roll, the specimen was allowed toequilibrate on the roll for a predetermined dwell time (0.5 minutes, 1minute, 5 minutes, or 10 minutes). After the predetermined dwell time,the tape was removed and the specimen was removed from the roll, takingspecial care not to deform the resultant U-shaped curved specimen. Thecurved specimen was placed on a hard benchtop surface at ambienttemperature (˜70° F.), with the bottom center of the U-shaped curvecontacting the bench top and the specimen ends pointing upward towardthe ceiling. The linear distance (in inches) between the two ends of thetest specimen was measured using a ruler at various relaxation times,the relaxation time starting from when the specimen was removed from theroll. Higher conformability values indicate lower conformability (e.g.,a conformability value of 13 inches after a short relaxation time for a13-inch test specimen indicates that test specimen was relatively rigid,having relaxed back to original flat form in a short period of time).Reported conformability results are an average of three measurements.

Examples 1A, 1B, and 1C

An adhesive, a tackified polyacrylate-based non-woven BMF-PSA, wasprepared substantially as described at column 18, lines 16-29 (AdhesiveSample 2) of U.S. Pat. No. 6,107,219 (Joseph et al.), onto aconventional polycoated liner. The basis weight of the adhesive wasabout 60 gsm (about 1.5 mil (0.04 mm) in thickness). A non-woven backingwas prepared substantially as described at column 19, lines 48-55(Backing Samples 8-10) of U.S. Pat. No. 6,107,219, except that HL-2812PT (an extrudable grade permanent pressure sensitive hot melt adhesiveavailable from H. B. Fuller, Minneapolis, Minn.) was used rather thanKRATON PSA, and the backing further contained 3 wt % of a tan pigment(comprised of pre-blended polyurethane (80/o)/pigment (20%) available asProduct No. FBPUR2103-85-AE TAN from Clariant Minneapolis, Minn., asdescribed at column 18 lines 55-63 of U.S. Pat. No. 6,107,219).

Three different non-woven backings were prepared at three differentbasis weights: Example 1A had a basis weight of about 100 gsm (about11.75 mil (0.298 mm) in thickness); Example 1B had a basis weight ofabout 150 gsm (about 14.17 mil (0.360 mm) in thickness); and Example 1Chad a basis weight of about 200 gsm (about 18.42 mil (0.468 mm) inthickness). Each of the non-woven backings were laminated to theadhesive using a laminator, substantially as described at column 22,lines 1-11 (Example 1) of U.S. Pat. No. 6,107,219. The resultingadhesive-coated backings had the following total basis weights (backingwith adhesive, excluding the liner): Example 1A: about 160 gsm (about13.25 mil (0.337 mm) in total thickness, excluding the liner): Example1B: about 210 gsm (about 15.75 mil (0.400 mm) in total thickness,excluding the liner); and Example 1C: about 260 gsm (about 19.92 mil(0.506 mm) in total thickness, excluding the liner).

The tensile strength and elongation of the adhesive-coated backing(liner free) in each of the down web and cross web directions asmeasured according to the Tensile and Elongation Test and results arepresented in Table 1 below. Table 1 further includes comparative tensilestrength and elongation data for commercially available tapes and wraps.

TABLE 1 Down Web and Cross Web Tensile Strength and Elongation Percentfor Various Examples and Comparative Examples. Tensile StrengthElongation (lbf) (%) Example 1A DW (2-inch gauge length) 5.39 (24.0 N)470.94 CW (1-inch gauge length) 4.26 (18.9 N) 648.32 Example 1B DW(2-inch gauge length) 8.30 (36.9 N) 522.05 CW (1-inch gauge length) 6.24(27.8 N) 635.31 Example 1C DW (2-inch gauge length) 10.57 (47.02 N)496.34 CW (1-inch gauge length) 9.53 (42.4 N) 612.47 Comparative DW(2-inch gauge length) 24.63 (109.6 N) 162.46 Example A CW (1-inch gaugelength) 36.07 (160.4 N) 42.58 Comparative DW (2-inch gauge length) 11.87(52.80 N) 108.29 Example B CW (1-inch gauge length) 27.61 (122.8 N)19.07 Comparative DW (2-inch gauge length) 17.93 (79.76 N) 229.09Example C CW (1-inch gauge length) 35.92 (159.8 N) 28.98 Comparative DW(2-inch gauge length) 14.76 (65.66 N) 195.37 Example D CW (1-inch gaugelength) 7.81 (34.7 N) 166.27 Comparative DW (2-inch gauge length) 20.58(91.54 N) 156.65 Example E CW (1-inch gauge length) 32.07 (142.7 N)43.47 Comparative DW (2-inch gauge length) 37.66 (167.5 N) 451.20Example F CW (1-inch gauge length) 45.35 (201.7 N) 22.16Comparative Example A: MUELLER KINESIOLOGY TAPE, BLACK 1-STRIP ROLLkinesiology tape from Mueller Sports Medicine (Prairie du Sac, Wis.).Comparative Example B: KT TAPE™ KINESIOLOGY THERAPEUTIC TAPE, ORIGINALBLACK cotton kinesiology tape from KT Health, LLC (American Fork, Utah).Comparative Example C: KT TAPE™ KINESIOLOGY THERAPEUTIC TAPE. PRO PINKsynthetic kinesiology tape from KT Health, LLC (American Fork, Utah).Comparative Example D: 3M™ COBAN™ self-adherent wrap available from 3MCompany (St. Paul, Minn.).Comparative Example E: ACE™ KINESIOLOGY TAPE available from 3M Company(St. Paul, Minn.).Comparative Example F: ACE™ ELASTIC BANDAGE available from 3M Company(St. Paul, Minn.).

Example 2

The reinforcing portion (a blown film foam) was prepared as follows. Aseven layer film was produced using a seven layer annular stack die(obtained under the trade designation “COEX 7-LAYER” (Type LF-400) fromLabtech Engineering, Samutprakam, Thailand). Airflow to the die wasmanually controlled to achieve a blow up ratio of about 2:1. The bubblewas subsequently collapsed about ten feet above die and rolled up. Thefeed materials were supplied by 7 independent 20 mm diameter extruders,each with about a 30:1 length to diameter ratio. A first extruder wasused to melt and extrude an extrudable pressure sensitive adhesive(obtained under the trade designation “KRATON MD6748” from Polyone, AvonLake. Ohio) into an inside channel of the annular stack die. A screwspeed of 30 revolutions per minute was used. The melt temperature wasmaintained at 180° C. A second, third, fourth, fifth and sixth extruderwere used to feed, to the next five channels of the annular stack die, ablend of an ethylene methyl acrylate (EMA) copolymer (obtained under thetrade designation “ELVALOY 1609” from Dupont, Wilmington, Del.) and amasterbatch pellet containing a 65% concentration of an expandablemicrosphere (obtained under the trade designation “EXPANCEL 950 MB 80”from Akzo Nobel, Amsterdam, Netherlands). The blend ratio was maintainedat 92% of the ethylene methyl acrylate and 8% of the microspheremasterbatch. Extruder speeds were maintained at 60 revolutions perminute. A seventh extruder was used to feed a low density polyethylene(LDPE) resin (obtained under the trade designation “PETROTHENE NA217000”from LyondellBasell, Houston. Tex.) to the outside channel of theannular stack die. A melt temperature of 190° C. was maintained. Theextruder speed for this resin was maintained at 70 revolutions perminute. Because the bubble was subsequently collapsed, and the innermostlayer of the film was a pressure-sensitive adhesive, the finished film,after edge trimming of the collapsed bubble, was in effect a five layerfilm where the outermost (or “skin”) layers were the LDPE, the centerlayer was the result of the joining of two layers of the pressuresensitive adhesive, and layers 2 and 4 were each the product of themerging, while in the melt, of five original layers of the EMA withexpandable microspheres. The blown film foam produced was 55-60 mil(1.40-1.52 mm) thick and designated as Example 2.

The blown film foam was tested for tensile properties, hardness, anddensity, as described above. The results are provided in Table 2, below.Additionally, a 118 mil (3.00 mm) thick commercially available foam(obtained under the trade designation “WOODBRIDGE #SM25WH” fromWoodbridge Polyurethane, Troy, Mich.), indicated as Comparative ExampleG in Table 2, was also tested.

TABLE 2 Tensile Properties, Hardness, and Density of Example 2 andComparative Foam. Shore Shore Tensile Elonga- A D Den- Strength tionHard- Hard- sity (lbf) (%) ness ness (g/cm³) Example 2 70 38 0.41 DW(2-in 21.6 22 gauge length) (96N) CW (1-in 17.8 16 gauge length) (79N)Comparative Too Too 0.04 Example G Soft Soft DW (2-in 3.4 360 gaugelength) (15N) CW (1-in 3.1 475 gauge length) (14N)

The blown film foams from Example 2 and Comparative Example G wereevaluated according to the Conformability Test, at ambient rolltemperature (˜70° F./˜21° C.) and at 90° F. (32° C., simulating humanskin temperature) roll temperature, as described above. ComparativeExample H was a flexible stabilizing bar, 7.94 inches (20.2 cm) inlength and 0.5 inches (1.27 cm) in width obtained from a commerciallyavailable adhesive knee support strip under the trade designation KTFLEX REINFORCED ADHESIVE STRIPS from KT Health. LLC, American Fork,Utah. Comparative Example H was evaluated in a similar fashion asdescribed in the Conformability Test, except that the flexiblestabilizing bar was used directly in the test without furthermodification. Notably, the key component to providing conformabilitymeasurement data is the conformability of the reinforcing portion. Theadhesive coated backing has a minimal impact on conformabilitymeasurement data.

The results are provided in Table 3, below.

TABLE 3 Dwell Time, Relaxation Time, and Relaxation Length at VaryingTemperatures. Dwell Relaxation Relaxation Temperature Time Time Length(° F.) (minutes) (minutes) (inches) Example 2 90 0.5 0.5  12 (30.5 cm)90 10 0.5 11.5 (29.2 cm) ~70 0.5 0.5 12.3 (31.2 cm) ~70 10 0.5  12 (30.5cm) Comparative 90 0.5 0.5  13 (33.0 cm) Example G 90 10 0.5  13 (33.0cm) ~70 0.5 0.5  13 (33.0 cm) ~70 10 0.5  13 (33.0 cm) Comparative 900.5 0.5 7.94 (20.2 cm) Example H 90 10 0.5 7.94 (20.2 cm) ~70 0.5 0.57.94 (20.2 cm) ~70 10 0.5 7.94 (20.2 cm)

It is apparent from Table 3 that Comparative Examples G and H werelargely non-conformable under the test conditions, with both relaxing totheir original length after a relaxation time of only 30 seconds.

Example 3 Shoulder Support Article

A shoulder support article as shown in FIG. 4 was made by laser cuttingthe adhesive-coated backing of the type described in Example 1B to theshape shown in FIG. 4. The reinforcing portion from Example 2 was lasercut to the shape shown in FIG. 4. The reinforcing portion was thenlaminated to the adhesive side of the adhesive coated backing. Aconventional liner was then applied to the adhesive face of the article(covering both the adhesive layer of the backing as well as thereinforcing portion). The length of the resulting article in the longestdirection was about 6.30 inches (16.0 cm).

The length of the reinforcing portion in the longest direction was about3.15 inches (8.00 cm). Approximately 85% of the surface area of theskin-facing side of the article was adhesive-coated (with the balance ofthe surface area occupied by the reinforcing portion). Other supportarticles described herein can be made in a similar fashion.

Example 4: Elbow Support Article

An elbow support article as shown in FIGS. 10 and 11A was made by lasercutting a adhesive-coated backing of the shape shown in FIG. 10 from thebacking/adhesive combination described in Example 1B. A reinforcingportion as shown in FIG. 11A was laser cut from the foam described inExample 2. The reinforcing portion was then laminated to the adhesiveside of the adhesive coated backing. A conventional liner was thenapplied to the adhesive face of the article.

The length of the support article in the longest direction was about5.47 inches (13.9 cm). The length of the reinforcing portion in thelongest direction was about 2.05 inches (5.21 cm). Approximately 89% ofthe surface area of the skin-facing side of the support article wasadhesive-coated (with the balance of the surface area occupied by thereinforcing portion). Other support articles described herein can bemade in a similar fashion.

Example 5: Knee Support Article

A first knee support article as shown in FIGS. 8A and 8B was made bylaser cutting an adhesive-coated backing of the shape shown in FIG. 8Afrom the backing/adhesive combination described in Example 1B. Tworeinforcing portions of the shape and relative size shown in FIG. 8Bwere laser cut from the forma described in Example 2. The reinforcingportion was then laminated to the adhesive side of the adhesive coatedbacking. A conventional liner was then applied to the adhesive face ofthe article (covering both the adhesive layer of the backing as well asthe reinforcing portions).

The length of the support article in the longest direction was about6.93 inches (17.6 cm). The length of the longest reinforcing portion inthe longest direction was about 3.15 inches (8.00 cm). Other supportarticles described herein can be made in a similar fashion.

Example 6

The support article of Example 6 was made as follows: a rectangularregion (1.0×2.0 inches, 2.54×5.08 cm) of WOODBRIDGE #SM25WH foam waslaminated to the adhesive-coated backing of Example 1B such that it wascentered in both directions on the adhesive face of the adhesive-coatedbacking, the long edge of the foam parallel to the long edge of thebacking.

Example 7

The support article of Example 7 was made as follows: a rectangularregion (1.0×2.0 inches, 2.54×5.08 cm) of the reinforcing portion ofExample 2 was laminated to the adhesive-coated backing of Example 1Bsuch that it was centered in both directions on the adhesive face of theadhesive-coated backing, the long edge of the reinforcing portionparallel to the long edge of the backing.

PICOPRESS Compression/Pressure Test Procedure

To test the ability of the support article to apply pressure, acommercially available portable digital pressure gauge was used(available from Microlab Elettronica S.a.s. Roncaglia di Ponte SanNicol{dot over (o)} (PD). Italy under the trade designation MICROLABPICOPRESS). The instrument utilizes circularly-shaped transducer (anair-inflatable plastic bladder that is 5 cm in diameter) made of abiocompatible material. The transducer is tethered to the digital gaugevia tubing. The transducer is placed between a test specimen (e.g., abandage or an adhesive support article) and a substrate (e.g., a limb orrigid cylinder). The instrument incorporates a micro pump which ismanually activated by introducing a known volume of air (2 mL) into thetransducer and the micro pump is equipped with a detection sensor. Thepressure detected by the transducer is measured by the digital gauge andvisualized by means of an alphanumeric display on the gauge andexpressed in mmHg.

Compression/Pressure Test Procedure A (PICOPRESS)

A rigid 3-inch (7.62 cm) diameter cylinder was used as a substrate (thecylinder was approximately 10-12 inches (25-64 cm) in length). Thecircularly-shaped transducer was adhered midway along the length of thecylinder with double-sided tape, and arranged such that the tetherconnecting the transducer to the digital gauge was generally parallel tothe long axis of the cylinder (the tether further being secured withsingle-sided adhesive tape). Application of the test specimen(rectangularly-shaped, 2 inches (5.08 cm)×4.5 inches (11.43 cm)) ontothe cylinder, over the transducer, involved two laboratory personnel.When fully placed, the test specimen was arranged on the cylinder suchthat the long edge of the specimen (i.e., the 4.5 inch edge) was wrappedaround a portion of the circumference of the cylinder (i.e., orthogonalto the cylinder axis), midway along the length of the cylinder, with thecenter of the transducer located between the center of the specimen andthe cylinder. First, the liner of the specimen was removed to expose theadhesive. Second, one of the short edges (i.e., a 2-inch edge) of thespecimen was adhered midway along the length of the cylinder, with theshort edge of the specimen 1 inch (2.54 cm) away from the center of thetransducer, such that when the specimen was fully placed (by wrappingthe specimen partly about the circumference of the cylinder), thetransducer would be centrally located underneath the test specimen. Thesecond short edge of the specimen was adhered to a paddle of acommercially available digital force gauge (available under the tradedesignation CHATILLON DFS from Ametek, Largo, Fla.). Using two hands,Person 1 held the cylinder with the axis of the cylinder parallel to thefloor, with one hand holding one end of the cylinder and the other handholding the other end, such that the first short edge was on top (facingthe ceiling rather than the floor) and visible to Person 1, FacingPerson 1, Person 2 pulled on the digital force gauge so as to apply 1 lb(4.45 N) of force to the specimen (i.e., force was applied in adirection parallel to the floor, with non-adhered portion of thespecimen also being parallel to the floor). While applying 1 lb offorce, Person 1 rotated the cylinder toward themselves until the testspecimen completely covered the transducer and the entire specimen wasalmost completely adhered to the cylinder with the exception of aportion of the second short edge of the specimen which was still adheredto the paddle. Person 1 then removed the second short edge portion fromthe paddle and adhered the remaining portion of the specimen onto thecylinder. The digital pressure gauge was then operated, injecting afixed quantity a fixed volume of air (2 mL) into the transducer andmeasuring the pressure. Pressure readings were obtained in triplicateand averaged.

Compression/Pressure Test Procedure B (PICOPRESS)

The procedure used in Pressure Test Procedure B was substantiallyidentical to that described for Pressure Test Procedure A, except thatafter removing the liner from the specimen, the center of the specimenwas held in place over the center of the transducer while applying 1 lbof force first to one edge while adhering that first edge to thecylinder and then applying 1 lb of force to the second edge whileadhering that second edge to the cylinder. In all cases, the specimenswere arranged such that the longest linear direction of the specimen waswrapped about the circumference of the cylinder (analogously to PressureTest Procedure A, for rectangular specimens), with the center of thetransducer located under the center of the specimen, between thespecimen and the cylinder. Results are presented in Table 5, below.

TABLE 5 Compression Results Pressure Pressure Test Procedure (mmHg(kPa)) Example 1B (backing alone) A 36.3 (4.84) Example 7 A 47.0 (6.27)Comparative Example I* A 38.3 (5.11) Comparative Example B A 34.0 (4.53)Comparative Example C A 32.0 (4.27) Example 4 (Elbow Support) B 46.70(.23)  Example 5 (Knee Support) B 43.70 (5.83)  Comparative Example J**B 26.7 (3.56) *Comparative Example I: NEXCARE ™ Soft'N Flex AdhesiveBandages, knee and ankle size from 3M Company, St. Paul, Minnesota.**Comparative Example J: KT FLEX ™ REINFORCED ADHESIVE STRIPS from KTHealth, LLC, American Fork, UT, (10 inches × 2 inches (25 cm × 5 cm)including a flexible stabilizing bar within the adhesive support strip.

Reference throughout this specification to “one embodiment,” “someembodiments,” “one or more embodiments” or “an embodiment,” whether ornot including the term “exemplary” preceding the term “embodiment,”means that a particular feature, structure, material, or characteristicdescribed in connection with the embodiment is included in at least oneembodiment of the certain exemplary embodiments of the presentdisclosure. Thus, the appearances of the phrases such as “in one or moreembodiments,” “in certain embodiments,” “in one embodiment” or “in anembodiment” in various places throughout this specification are notnecessarily referring to the same embodiment of the certain exemplaryembodiments of the present disclosure. Furthermore, the particularfeatures, structures, materials, or characteristics may be combined inany suitable manner in one or more embodiments.

The recitation of all numerical ranges by endpoint is meant to includeall numbers subsumed within the range (i.e., the range 1 to 10 includes,for example, 1, 1.5, 3.33, and 10). Throughout this document, valuesexpressed in a range format should be interpreted in a flexible mannerto include not only the numerical values explicitly recited as thelimits of the range, but also to include all the individual numericalvalues or sub-ranges encompassed within that range as if each numericalvalue and sub-range is explicitly recited. For example, a range of“about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted toinclude not just about 0.1% to about 5%, but also the individual values(e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1%to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “aboutX to Y” has the same meaning as “about X to about Y,” unless indicatedotherwise. Likewise, the statement “about X, Y, or about Z” has the samemeaning as “about X, about Y, or about Z,” unless indicated otherwise.

In this document, the terms “a,” “an,” or “the” are used to include oneor more than one unless the context clearly dictates otherwise. The term“or” is used to refer to a nonexclusive “or” unless otherwise indicated.The statement “at least one of A and B” has the same meaning as “A, B,or A and B.” In addition, it is to be understood that the phraseology orterminology employed herein, and not otherwise defined, is for thepurpose of description only and not of limitation. Any use of sectionheadings is intended to aid reading of the document and is not to beinterpreted as limiting; information that is relevant to a sectionheading may occur within or outside of that particular section.

In the methods described herein, the acts can be carried out in anyorder without departing from the principles of the disclosure, exceptwhen a temporal or operational sequence is explicitly recited.Furthermore, specified acts can be carried out concurrently unlessexplicit claim language recites that they be carried out separately. Forexample, a claimed act of doing X and a claimed act of doing Y can beconducted simultaneously within a single operation, and the resultingprocess will fall within the literal scope of the claimed process.

The polymers described herein can terminate in any suitable way. In someembodiments, the polymers can terminate with an end group that isindependently chosen from a suitable polymerization initiator, —H, —OH,a substituted or unsubstituted (C₁-C₂₀) hydrocarbyl (e.g., (C₁-C₁₀)alkylor (C₆-C₂₀)aryl) interrupted with 0, 1, 2, or 3 groups independentlyselected from —O—, substituted or unsubstituted —NH—, and —S—, apoly(substituted or unsubstituted (C₁-C₂₀)hydrocarbyloxy), and apoly(substituted or unsubstituted (C₁-C₂₀)hydrocarbylamino).

The terms first, second, third and the like in the description and inthe claims, are used for distinguishing between similar elements and notnecessarily for describing a sequential or chronological order. It is tobe understood that the terms so used are interchangeable underappropriate circumstances and that the embodiments of the inventiondescribed herein are capable of operation in other sequences thandescribed or illustrated herein.

Moreover, the terms top, bottom, over, under and the like in thedescription and the claims are used for descriptive purposes and notnecessarily for describing relative positions. It is to be understoodthat the terms so used are interchangeable under appropriatecircumstances and that the embodiments of the invention described hereinare capable of operation in other orientations than described orillustrated herein.

All references mentioned herein are hereby incorporated by reference intheir entirety.

With reference to the Figures, like numerals are used to designate likecomponents throughout the set of Figures.

Those having skill in the art will appreciate that many changes may bemade to the details of the above-described embodiments andimplementations without departing from the underlying principlesthereof. Further, various modifications and alterations of the presentinvention will become apparent to those skilled in the art withoutdeparting from the spirit and scope of the invention. The scope of thepresent application should, therefore, be determined only by thefollowing claims and equivalents thereof.

What is claimed is:
 1. A support article, comprising: a backing having afront major surface and a rear major surface; an adhesive adjacent toleast a portion of the rear major surface of the backing, the adhesivecapable of adhering the support article to the user; and one or morereinforcing portions adjacent to at least a portion of the rear majorsurface of the backing or the front major surface of the backing,wherein the one or more reinforcing portions comprise: an adhesive layerhaving first and second major surfaces; a first foam layer adjacent tofirst major surface of the adhesive layer; a second foam layer adjacentto second major surface of the adhesive layer; a first skin layeradjacent to first foam layer; and a second skin layer adjacent to secondfoam layer.
 2. The support article of claim 1, further including arelease liner adjacent to at least a portion of the adhesive.
 3. Thesupport article of claim 1, wherein the backing includes at least one ofa polyurethane film, a polyethylene film, a polypropylene film, a PVCfilm, a nonwoven material, and/or a woven material.
 4. The supportarticle of claim 1, wherein the backing includes at least one of apolyolefin, polyester, polyalkylene, polyamide, polystyrene,polyarylsulfone, polydiene, and/or polyurethane.
 5. The support articleof claim 1, wherein the backing includes conjugate multicomponent meltspun fibers.
 6. The support article of claim 1, wherein at least one ofthe backing or the backing and adhesive combination has a breathabilityand/porosity of between about 3 and about 12 mm H₂O measured using thepressure drop test.
 7. The support article of claim 1, wherein at leastone of the backing or the backing and adhesive combination has across-directional tensile strength of between about 4 lbf (17.8 N) andabout 9 lbf (40.0 N) and/or a machine-directional tensile strength ofbetween about 5 lbf (22.2 N) and about 10 lbf (44.5 N).
 8. The supportarticle of claim 1, wherein at least one of the backing or the backingand adhesive combination has a cross-directional elongation at break ofbetween about 600% and about 900% and/or a machine-directionalelongation at break of between about 350% and about 1000%.
 9. Thesupport article of claim 1, wherein the adhesive is a pressure sensitiveadhesive and is selected from at least one of the following adhesiveclasses: polyacrylate adhesives, polyalphaolefin adhesives, polyvinylacrylates, rubber resin adhesives, silicone adhesives,polydiorganosiloxane polyurea compolymers, and mixtures thereof.
 10. Thesupport article of claim 1, wherein the backing and adhesive form aconjugate multicomponent system.
 11. The support article of claim 1,wherein the reinforcing portion(s) cover between about 10% and about75%.
 12. The support article of claim 1, wherein the one or morereinforcing portions include at least one of foam or a shaped memorymaterial.
 13. The support article of claim 1, further includingmicrospheres in at least one of the first or second foam layers.
 14. Thesupport article of claim 1, wherein the one or more reinforcing portionshas a Shore A hardness is between about 10 and about 100 when measuredaccording to ASTM D2240 and/or a Shore D hardness of between about 10and about 60 when measured according to ASTM D2240.
 15. The supportarticle of claim 1, wherein the one or more reinforcing portions has across-directional tensile strength of between about 13 lbf (57.8 N) andabout 28 lbf (129.0 N) and/or a machine-directional tensile strength ofbetween about 16 lbf (71.2 N) and about 31 lbf (137.9 N).
 16. Thesupport article of claim 1, wherein the one or more reinforcing portionshave an elongation at break of between about 10% and about 50%.
 17. Thesupport article of claim 1, comprising at least two reinforcing portionsthat are on layered on one another.
 18. The support article of claim 1,wherein at least one of the reinforcing portions is separate from thesupport article and can be independently applied by the user before thefull support article is applied.
 19. A method of applying a supportarticle of claim 1, comprising: removing a liner from a rear majorsurface of the support article to expose an adhesive; positioning thesupport article adjacent to a user's body in a desired location;applying the support article to the user such that the adhesive contactsthe user's skin; and putting pressure on the support article to causethe adhesive to adhere to the user's skin.